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This report presents the findings of a research study conducted to develop procedures for the design of structural HMA overlays over existing flexible pavements in Wisconsin. The recommended procedures are presented in a hierarchal approach to allow the user the flexibility of estimating the effective structural number of an in-place HMA pavement based on visual and/or nondestructive deflection testing data and to develop overlay thickness requirements based on the structural deficiency approach.
The objective of this research was to develop an overlay design method/procedure that is used for a structural overlay thickness design of flexible pavement in Louisiana based upon (1) in-situ pavement conditions and (2) non destructive test (NDT) methods, specifically the falling weight deflectometer (FWD) and/or Dynaflect. Fifteen overlay rehabilitation projects were selected for this study. These projects were strategically located throughout Louisiana with different traffic levels. At each selected project, NDT deflection tests including the falling weight deflectometer (FWD) and Dynaflect were performed at a 0.1-mile interval. For some of the selected projects, detailed condition survey data including cracking, rut depth, International Roughness Index (IRI), mid-depth temperature, and pavement thickness was also collected. Six NDT-based overlay design methods were selected and used in the overlay thickness design analysis.