Review of ODOT's overlay design procedure: volume 1 of 2: HMA overlays of existing HMA and composite pavements

ODOT initiated this research study to determine (1) the impact of milling off portions of the existing pavement on the structural capacity of the remaining pavement and (2) whether currently recommended HMA structural coefficients adequately reflect the structural properties of new HMA overlay materials. The study mainly focused on the impact of milling on the design of HMA overlays over existing flexible pavements and composite pavements. This volume (Volume I) of the report deals with this main study focus area. During the course of the study, an additional focus area was added to the project to investigate the impact of completely milling off existing HMA layers in composite pavement systems on unbonded overlay design. Volume II of this report deals with impact of milling on unbonded overlays. This report describes the structural evaluation of individual flexible and composite pavement projects located at different sites throughout Ohio, as well as an analysis of the evaluation results to develop enhancements to the ODOT HMA overlay design procedure as needed. The report presents detailed descriptions of the projects evaluated, field testing procedures employed, procedures adopted for analyzing field testing data and other data collected, structural evaluation results, analysis of results, and recommendations for improvements of the current ODOT overlay design procedure.