Lecture 19

Design of Overlays
(Concrete or Asphaltic Overlay)
 Purpose of Overlay

❑ Increase load carrying capacity of an existing pavement

❑ Correct a defective surface condition of an existing pavement
❑ Pavement maintenance
❑ Pavement quality
❑ Strengthening a pavement
 Types of Overlays
 Bituminous overlay over bituminous pavements
 Bituminous overlays on concrete pavements
 Concrete overlays on Bituminous pavements
(White-topping)
 Concrete overlays on concrete pavements
 Objectives

❑ Understanding different types of overlays

❑ Design asphaltic overlays based on Benkelman Beam Deflection: IRC81 - 1997

❑ Design asphaltic overlays based on Falling Weight Deflectometer :IRC SP 115-2014

❑ Design concrete overlays (white-topping): IRC SP: 76-2008 (Now 2015)

 Overlay Design Methodologies

 Deflection approach (Benkelman Beam Deflection)

 Mechanistic- empirical approach (FWD)
 Deflection Approach

 Larger pavement surface deflections imply weaker pavement and

Subgrade and thus require thicker overlays
 The overlay must be thick enough to reduce the deflection to tolerable
amount
 Benkelman beam is used for measuring rebound deflections
Mechanistic- Empirical approach (Deflection-Modulus-Distress)

 First calculate remaining life of existing pavement based on failure

criteria
 fatigue
cracking
 permanent deflection

 Based on remaining life thickness of overlay is then determined so that

damages in new overlay is in allowable limits
 Falling weight deflectometer (FWD) is used for estimating remaining life
 Asphaltic Overlay
Asphaltic Overlay
Benkelman Beam White-topping
FWD: IRC115-2014
Deflection: IRC81 - 1997 IRC:SP-76-2008
 Asphaltic Overlay
Benkelman Beam Deflection: IRC81 - 1997
 Benkelman Beam: IRC: 81- 1997
 A.C. Benkelman (USA)- 1953
 Used in India for last 2-3 decades (First IRC code in 1981)
 Overlay design based on rebound deflection of existing pavement
 Strengthening of an existing flexible pavement
 Static load
 Factors affecting deflection of a pavement:
o Subgrade type (soil type)
o Moisture
o Temperature
o Thickness of pavement layer(s)
o Compaction of pavement layer
o Drainage condition

IRC: Indian Road Congress

 Preparation for Conducting
Benkelman Beam Test
❑ Benkelman Beam apparatus
❑ Truck with a rear standard axle weight = 8 ton (80 kN)
❑ Tire pressure = 5.6 kg/cm2 (0.56 MPa)
❑ Axle type = dual wheel single axle
❑ Thermometer for measurement of temperature
❑ Accessories for collection of soil, moisture
❑ Measuring Tape
❑ Traffic data (growth rate, distribution factor,
vehicle no., million standard axle - msa)
❑ Calibration of Benkelman Beam

80 kN

Standard Axle
 Deflections:
• Initial Reading – Do (Start point)
• Intermediate reading - Di (truck moves to 2.7 m
away from the start point)
• Final reading – Df (truck moves to 9 m away from
the start point)

Dial guage
Toe of Probe
2.44 m d2

d1 1.22 m

d1= 2.d2
d1= pavement rebound deflection
d2 = dial gauge reading
We measured dial guage reading in the field
 Location of Benkelman Beam Test

 Marking of wheel path from a pavement edge

➢ 0.6 m for lane width < 3.5 m
➢ 0.9 m for lane width > 3.5 m
➢ 1.5 m for divided four lane highway

1 3 5 7

2 4 6 8

Not more than 50 m

Video Benkelman Beam Test
 Corrections
• Initial Dial Gauge Reading – Do
• Intermediate Dial Gauge Reading - Di
1. Leg Correction • Final Dial Gauge Reading – Df

- If (Di - Df) ≤ 0.025 mm, Rebound Deflection, D = 2(D0 – Df )

- If (Di - Df) > 0.025 mm, Rebound Deflection, D = [ 2 (D0 – Df) + 5.82 (Di – Df) ]

2.Temperature Correction
 Temperature corrections
o Standard reference temperature = 35 C
o Correction =0.01 mm/ C (adjust field measurement reading to standard reference temperature)
o Corrected deflection: measured deflection + (35 - T)*0.01
Example:
Field temperature = 40 C, measured deflection = 1.5 mm
Deflection at a reference temperature (35 C) = 1.5 + (35 - 40)*0.01= 1.45 mm
3. Seasonal Correction

 Seasonal Variation and Subgrade Type

Rainfall,
Moisture Content
Plasticity Index of soil

Deflection values corrected for temperature

shall be multiplied by the appropriate values of
seasonal correction factors to obtain correct value of
deflection

Example:
Moisture Content= 9%,
Moisture correction factor = 1.02
Temperature correction deflection = 1.5 mm
Final corrected deflection = 1.5x 1.02 = 1.53 mm
 DATA SHEET FOR RECORDING BENKELMAN BEAM DEFLECTION READINGS

Soil Type:

Annual Rainfall:
Moisture
Content Soil
Reading mm Data From BBD Survey
Temperature, Intermediate Final Moisture Rebound Mean Std. Characteristics
Point C Initial Reading Reading Readings Rebound Temp. Corr Corr Def Def Dev. Def
1 Chainage - 0
2 Chainage - 50
3 Chainage - 100
4 Chainage - 150
5 Chainage - 200
6 Chainage - 250
7 Chainage - 300
8 Chainage - 350
9 Chainage - 400
 Steps – BBD Overlay Design
Step 1: Measure BBD deflection at several points along length of a pavement
Step 2: Apply leg correction to the deflection readings, if any
Step 3: Apply temperature and seasonal correction and calculate final deflection
Step 4: Estimate correct rebound deflection for all points
Step 5: Calculate average and standard deviation of final deflection
Step 6: Estimate characteristic deflection
1. NH/SH: Dc = ( D + 2 σ )
2. Other Roads: Dc = ( D + σ )
D = mean final corrected deflection
Step 7: Estimate traffic
Step 8: Find overlay thickness from graph

1 3 5 7

2 4 6 8

Not more than 50 m

1 cm BM = 1.5 cm WBM/WMM
1 cm BM = 0.7 cm DBM/BC
Pavement Riding Quality: The riding quality of the pavement shall be ensured by stratifying the
minimum requirement given herein under:
i) Surface roughness of the project highway on completion of construction shall be 2000 mm/km
as measured by vehicle mounted Bump Integrator
ii) Surface roughness shall not exceed 3000 mm/km during service life of pavement at any time. A
renewal coat of bituminous concrete shall be laid every 5 year after initial construction or where
the roughness value reaches 3000 mm/km whichever is earlier to bring it to the initial value of
2000 mm/km

Structural Condition of the Pavement:

i) The structural condition of the flexible pavement of the project highway shall be assessed every
year by taking Benkelman Beam Deflection and working out characteristic deflection of
homogeneous sections of the project highways as per IRC81-1997. Wherever the characteristics
deflection exceeds 1.2 mm a bituminous overlay shall be provided appropriately designed
accordingly to IRC81:1997 or its latest versions or amendments to it.
ii) Surface roughness shall not exceed 3000 mm/km during service life of pavement at any time. A
renewal coat of bituminous concrete shall be laid every 5 year after initial construction or where
the roughness value reaches 3000 mm/km whichever is earlier to bring it to the initial value of
2000 mm/km
 Overlay Design Using BBD - (Class Exercise)

The BBD test was conducted on an existing NH pavement. Bituminous layer thickness: 100 mm, aggregate
layer: 450 mm, design traffic: 20 msa, subgrade moisture content = 12%, clayey soil, PI>15, average annual rain
fall = >1300 mm

If traffic is not given then calculate

based on ADT, D, r, n,VDF

Check Sheet for

Example and Do
Calculation
 Class Exercise: Example – Design of Overlay BBD Solution
• Di-Df
• Moisture correction:
• Mean Deflection:
• Standard deviation:
• Characteristics Deflection:
Soil Type: PI>15
• From chart for 20 msa,
Annual Rainfall >1300 mm
Moist Content Soil 12%
• BM: ……….mm
Traffic 20 msa • BC/DBM: BM*0.7 = ……..mm
Road Type NH
Reading mm Data From BBD Survey
Do: Initial Dial Di: Intermediate Df: Final Dial Rebound Corrected
Guage Dial Guage Guage Def. After Temp. Moisture Rebound Characteri
Point Temp, C Reading Reading Reading Di-Df Do-Df Leg Corr. Corr Corr Def Mean Def Std. Dev. stics Def

1 40 8.45 8.21 8.15

2 38 13.25 13.01 12.9

3 36 16.36 16.13 16.04
4 36 9.65 9.41 9.33
5 38 15.24 15.03 14.98
6 37 19.68 19.42 19.32
7 35 17.44 17.13 17.06
8 30 8.13 7.91 7.85
9 29 12.05 11.76 11.66
10 28 10.19 9.99 9.9

- If (Di - Df) ≤ 0.025 mm, Rebound Deflection, D = 2(Do – Df ) O Corrected deflection: measured deflection + (35- T) 0.01
- If (Di - Df) > 0.025 mm, Rebound deflection, D = [ 2 (Do – Df) + 5.82 (Di – Df) ]
 Soil Type: PI>15
Annual Rainfall > 1300 mm - If (Di - Df) ≤ 0.025 mm, Rebound Deflection, D = 2(D o – Df )
Moist Content Soil 12%
Traffic 20 msa - If (Di - Df) > 0.025 mm, Rebound deflection, D = [ 2 (D o – Df) + 5.82 (Di – Df) ]
Road Type NH
Reading mm Data From BBD Survey
Do: Initial Dial Di: Intermediate Df: Final Dial Rebound Corrected
Guage Dial Guage Guage Def. After Temp. Moisture Rebound Characteri
Point Temp, C Reading Reading Reading Di-Df Do-Df Leg Corr. Corr Corr Def Mean Def Std. Dev. stics Def
1 40 8.45 8.21 8.15 0.06 0.3
2 38 13.25 13.01 12.9 0.11 0.35
3 36 16.36 16.13 16.04 0.09 0.32
4 36 9.65 9.41 9.33 0.08 0.32
5 38 15.24 15.03 14.98 0.05 0.26
6 37 19.68 19.42 19.32 0.1 0.36
7 35 17.44 17.13 17.06 0.07 0.38
8 30 8.13 7.91 7.85 0.06 0.28
9 29 12.05 11.76 11.66 0.1 0.39
10 28 10.19 9.99 9.9 0.09 0.29
oCorrected deflection: measured deflection + (35- T) 0.01
 Soil Type: PI>15
Annual Rainfall > 1300 mm
Moist Content Soil 12%
Traffic 20 msa
Road Type NH
Reading mm Data From BBD Survey
Do: Initial Dial Di: Intermediate Df: Final Dial Rebound Corrected
Guage Dial Guage Guage Def. After Temp. Moisture Rebound Characteri
Point Temp, C Reading Reading Reading Di-Df Do-Df Leg Corr. Corr Corr Def Mean Def Std. Dev. stics Def
1 40 8.45 8.21 8.15 0.06 0.3 0.95
2 38 13.25 13.01 12.9 0.11 0.35 1.34
3 36 16.36 16.13 16.04 0.09 0.32 1.16
4 36 9.65 9.41 9.33 0.08 0.32 1.11
5 38 15.24 15.03 14.98 0.05 0.26 0.81
6 37 19.68 19.42 19.32 0.1 0.36 1.30
7 35 17.44 17.13 17.06 0.07 0.38 1.17
8 30 8.13 7.91 7.85 0.06 0.28 0.91
9 29 12.05 11.76 11.66 0.1 0.39 1.36
10 28 10.19 9.99 9.9 0.09 0.29 1.10
 Soil Type: PI>15
Annual Rainfall > 1300 mm
Moist Content Soil 12%
Traffic 20 msa
Road Type NH
Reading mm Data From BBD Survey
Do: Initial Dial Di: Intermediate Df: Final Dial Rebound Corrected
Guage Dial Guage Guage Def. After Temp. Moisture Rebound Characteri
Point Temp, C Reading Reading Reading Di-Df Do-Df Leg Corr. Corr Corr Def Mean Def Std. Dev. stics Def
1 40 8.45 8.21 8.15 0.06 0.3 0.95 0.90
2 38 13.25 13.01 12.9 0.11 0.35 1.34 1.31
3 36 16.36 16.13 16.04 0.09 0.32 1.16 1.15
4 36 9.65 9.41 9.33 0.08 0.32 1.11 1.10
5 38 15.24 15.03 14.98 0.05 0.26 0.81 0.78
6 37 19.68 19.42 19.32 0.1 0.36 1.30 1.28
7 35 17.44 17.13 17.06 0.07 0.38 1.17 1.17
8 30 8.13 7.91 7.85 0.06 0.28 0.91 0.96
9 29 12.05 11.76 11.66 0.1 0.39 1.36 1.42
10 28 10.19 9.99 9.9 0.09 0.29 1.10 1.17
 Soil Type: PI>15
Annual Rainfall > 1300 mm
Moist Content Soil 12%
Traffic 20 msa
Road Type NH
Reading mm Data From BBD Survey
Do: Initial Dial Di: Intermediate Df: Final Dial Rebound Corrected
Guage Dial Guage Guage Def. After Temp. Moisture Rebound Characteri
Point Temp, C Reading Reading Reading Di-Df Do-Df Leg Corr. Corr Corr Def Mean Def Std. Dev. stics Def
1 40 8.45 8.21 8.15 0.06 0.3 0.95 0.90
2 38 13.25 13.01 12.9 0.11 0.35 1.34 1.31
3 36 16.36 16.13 16.04 0.09 0.32 1.16 1.15
4 36 9.65 9.41 9.33 0.08 0.32 1.11 1.10
5 38 15.24 15.03 14.98 0.05 0.26 0.81 0.78
1.2
6 37 19.68 19.42 19.32 0.1 0.36 1.30 1.28
7 35 17.44 17.13 17.06 0.07 0.38 1.17 1.17
8 30 8.13 7.91 7.85 0.06 0.28 0.91 0.96
9 29 12.05 11.76 11.66 0.1 0.39 1.36 1.42
10 28 10.19 9.99 9.9 0.09 0.29 1.10 1.17
 Soil Type: PI>15
Annual Rainfall > 1300 mm
Moist Content Soil 12%
Traffic 20 msa
Road Type NH
Reading mm Data From BBD Survey
Do: Initial Dial Di: Intermediate Df: Final Dial Rebound Corrected
Guage Dial Guage Guage Def. After Temp. Moisture Rebound Characteri
Point Temp, C Reading Reading Reading Di-Df Do-Df Leg Corr. Corr Corr Def Mean Def Std. Dev. stics Def
1 40 8.45 8.21 8.15 0.06 0.3 0.95 0.90 1.08
2 38 13.25 13.01 12.9 0.11 0.35 1.34 1.31 1.57
3 36 16.36 16.13 16.04 0.09 0.32 1.16 1.15 1.38
4 36 9.65 9.41 9.33 0.08 0.32 1.11 1.10 1.31
5 38 15.24 15.03 14.98 0.05 0.26 0.81 0.78 0.94
1.2
6 37 19.68 19.42 19.32 0.1 0.36 1.30 1.28 1.54
7 35 17.44 17.13 17.06 0.07 0.38 1.17 1.17 1.40
8 30 8.13 7.91 7.85 0.06 0.28 0.91 0.96 1.15
9 29 12.05 11.76 11.66 0.1 0.39 1.36 1.42 1.71
10 28 10.19 9.99 9.9 0.09 0.29 1.10 1.17 1.41
 Soil Type: PI>15
Annual Rainfall > 1300 mm
Moist Content Soil 12%
Traffic 20 msa
Road Type NH
Reading mm Data From BBD Survey
Do: Initial Dial Di: Intermediate Df: Final Dial Rebound Corrected
Guage Dial Guage Guage Def. After Temp. Moisture Rebound Characteri
Point Temp, C Reading Reading Reading Di-Df Do-Df Leg Corr. Corr Corr Def Mean Def Std. Dev. stics Def
1 40 8.45 8.21 8.15 0.06 0.3 0.95 0.90 1.08
2 38 13.25 13.01 12.9 0.11 0.35 1.34 1.31 1.57
3 36 16.36 16.13 16.04 0.09 0.32 1.16 1.15 1.38
4 36 9.65 9.41 9.33 0.08 0.32 1.11 1.10 1.31
5 38 15.24 15.03 14.98 0.05 0.26 0.81 0.78 0.94
1.2 1.35 0.24 1.82
6 37 19.68 19.42 19.32 0.1 0.36 1.30 1.28 1.54
7 35 17.44 17.13 17.06 0.07 0.38 1.17 1.17 1.40
8 30 8.13 7.91 7.85 0.06 0.28 0.91 0.96 1.15
9 29 12.05 11.76 11.66 0.1 0.39 1.36 1.42 1.71
10 28 10.19 9.99 9.9 0.09 0.29 1.10 1.17 1.41
1 cm BM = 1.5 cm WBM/WMM
1 cm BM = 0.7 cm DBM/BC