Hanson, Chelsea E.

The National Road Research Alliance (NRRA); a multi-state pooled-fund program; exists to provide strategic implementation of pavement engineering solutions through cooperative research. NRRA is led by an Executive Committee of state DOT partners; and supported by numerous agency and industry partner representatives. Members provide expertise to NRRA; from the selection of research topics; to communication; and implementation. NRRA consists of five project teams: Flexible; Rigid; Geotechnical; Preventive Maintenance; and Technology Transfer. The 2017 construction season at MnROAD saw construction of 35 new and unique pavement test sections. The sections; designed to address NRRA high-priority research topics; were conceived and planned by NRRA project teams. This report details development; design; and construction of each research project and the test sections supporting them. Individual study details are left to future reports generated by the individual research contracts and their respective teams.

This report presents the findings from an eight-year performance evaluation of eight cells (Cells 16-23) built at the Minnesota Road Research Facility (MnROAD) in 2008. The constructed cells were used for two performance evaluation studies of: 1) unbound base materials (i.e.; recycled asphalt pavement (RAP); recycled concrete aggregate (RCA); and taconite) and Class 5 aggregate as the road base material and 2) surface materials that include warm mix additives (WMAs); RAP; and different binders with different performance grades. The eight cells were tested via a surface distress survey; rutting tests; falling weight deflectometer tests; international roughness index (IRI) tests; and friction tests. Disk-shaped compact tension (DCT) tests also were performed using the mixture samples; and the performance of the unbound base materials (Cells 16-19) was evaluated using light-weight deflectometer (LWD); dynamic cone penetrometer (DCP); and gradation tests. After eight years of service (approximately 5.6 million equivalent single-axle loads); the cells remained in good condition in terms of their resistance to surface distresses; rutting; stiffness; IRI values; and friction. Consequently; it was difficult to compare the performance of the various unbound materials and mixtures. The unbound recycled materials and taconite performed as well as the Class 5 aggregate base material in terms of the gradation; DCP; and LWD test results. All mixture types; regardless of RAP content; binder grade; or the presence of WMA; exhibited similar performance.

The asphalt mixture design and acceptance procedures for Minnesota Department of Transportation are currently governed primarily by the mixture composition requirements put forth through use of various volumetric measures (such as, air content, asphalt film thickness, aggregate gradation etc.). The asphalt binder has been required to meet performance criteria through the Superpave asphalt binder specifications. This study looked at use of laboratory performance test for asphalt mixtures. The study was conducted in three phases, first phase focused on merging the asphalt mix design records with the pavement performance data to determine effects of mix design parameters on asphalt pavement cracking performance. Second and third phase used a series of field sections across Minnesota to conduct field performance evaluations as well as laboratory tests on field cored samples. The testing for second an third phase of the study focused on using disk-shaped compact tension (DCT) fracture energy test as a laboratory performance test. The findings form he first phase of study indicated that the asphalt binder type as defined by the Superpave performance grade (PG) plays an important role in affecting the field cracking performance, majority of mixture design parameters did not indicate a consistent effect on field cracking performance, this reinforces the need for use of laboratory performance test as a mixture design tool as well as acceptance parameter. The DCT testing results showed trends consistent with previous and other on-going research studies, whereby the asphalt mixtures with higher fracture energies corresponded with pavements with lower amount of transverse cracking.

This report summarizes efforts of using the disk-shaped compact tension (DCT) test to measure thermal fracture properties of asphalt mixtures on five asphalt paving projects in Minnesota during the 2013 construction season. Five construction projects throughout the state were chosen by a team of researchers at the Minnesota Department of Transportation (MnDOT) and University of Minnesota Duluth (UMD) representing differing climatic conditions, construction practices, and asphalt PG binder grades. Contractors from these varying projects provided UMD with mix design and production pills and MnDOT with loose production mix and raw materials for specimen fabrication. Testing was done to verify mixes met the required fracture energy value of 400 J/m2. If DCT results did not meet this requirement, mix adjustment recommendations were made by the research team. When recommendations were accepted, test sections with adjusted mix were paved. DCT testing was conducted on both adjusted and unadjusted production mix. Results of these efforts showed a drop in fracture energy between mix design and production for each project. The cause is not known at this time, but will be investigated in future research. Preliminary distress surveys indicated projects with mill and overlay experienced higher amounts of cracking compared to projects with reclaim or new construction. It should be noted distress surveys were conducted 9 months after initial paving, with the roadways subjected to only one season of freezing conditions. Condition of underlying pavement structure was not investigated before paving began in the cases of mill and overlays