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I-60.NCSA.68
A Simple Guide
for the
DESIGN OF FLEXIBLE PAVEMENTS
USING CRUSHED STONE
National Crushed Stone Association
op,
FOREWORD
In 1965, the National Crushed Stone Association issued
its Statement of Policy With Respect to the AASHO Road
Test. Since then, many authorities have agreed with NCSA's
position and refuse to accept the so-called layer equivalency
concept which evolved from the findings of the Road Test.
One in particular, the world-renowned Francis N. Hveem, in
his 1968 NCSA Convention paper said:
'I have always deplored the use of this
term in the engineering design of pave-
ments......It enables salesmen or promot-
ers of some particular type of pavement
to pose as engineers. Too much depends
upon the circumstances, the nature of
materials, climatic conditions and above
all, the weight of traffic, to justify any
such concept as an 'equivalency ratio'
f
ixed
for all materials and conditions.'
This guide for the design of flexible pavements has been
reviewed and approved by NCSA's Technical Committee.
Questions regarding any of the information it contains should
be directed to Frank P. Nichols, Jr., NCSA's Engineering
Director. We feel that this publication will assist you in the
se1ction of material types and thicknesses for a variety of
pavement design situations.
W. L. Carter
Executive Director
March 1968
INTRODUCTION
The design of flexible pavements appears more and more
complex as more and more research is performed. Basically,
however, the observation of certain fundamental principles in
design and construction can usually result in successful and
serviceable structures at modest cost.
The typical flexible pavement should embrace three
main elements. The firstperhaps the most important though
often given the least considerationis the
foundation, either
a firm, unyielding subbase or a stabilized or otherwise im-
proved suhgrade. The second is the
base.
whose function is to
transmit and cushion wheel load stresses to an extent that the
foundation and subgrade are not overstressed. The third is
the bituminous mat,
a combination of layers of aggregates
and bituminous binders whose function is to resist abrasion,
tangential stresses from acceleration and deceleration, and the
infiltration of moisture. The following notes have been pre-
pared to provide guidance to engineers and architects charged
with the selection of materials and methods of construction
for these elements. Emphasis is laid on the advantages and
the proper use of dense graded crushed stone for the founda-
tion and base courses.
THE FOUNDATION,OR IMPROVED SUBGRADE
Construction of a proper foundation for a flexible pave-
ment structure should involve considerably more than just
smoothing up the native soil and rolling it, although in a few
isolated areas this may be about all that is necessary. The
mere fact that the bare soil is smooth and hard and can sup-
port heavy loads when fairly dry is poor insurance against
subsequent loss of support. If the native soil cannot be made
permanently stable and essentially non-resilient under all an-
ticipated conditions of load and weather, it should be strength-
ened by one of several proven methods. Attempts to "bridge
over" weak subgrades by use of thin semi-rigid bases or by
thickening the bituminous mat have resulted in some costly
failures.
Blanket of Granular Material
The most popular method of foundation preparation in-
volves a granular material blanket of such thickness that, it is
believed, the native soil is beyond the depth of frost penetra-
tion or the influence of applied loads. Research has shown,
however, that legal wheel loads are often felt to depths of sev-
eral feet, deeper in most cases than the frost line. Soils which
are resilient or lacking in shear strength, even though blanket-
ed to a depth great enough to protect them from freezing,
may still be stressed enough to cause damaging deflections or
permanent deformations under repeated heavy loadings. Fig-
ure 1 shows fatigue cracking caused primarily by resiliency of
the foundation layer.
Figure 1. Surface distress commonly associated with inadequate support at the
foundation level.
-
dr
Available test methods, such as the California Bearing
Ratio test, ASTM Standard Method D
1883,*
may give some
idea of the shear strength of the soils involved, but standard
tests for resiliency are still in the developmental stage. The
presence of a high percentage of silt sized particles, and more
particularly the presence of shiny flakes of mica, may be a
danger sign foreboding critical resiliency that will lead in time
to serious fatigue cracking of the bituminous surface. Perhaps
the only reliable indication of the supporting power of the
native soil is the performance of highways in adjacent areas.
Local granular materials from roadside pits often lack
stability or may be resilient themselves and thus will not per-
form the functions of a foundation layer. Some areas, how-
ever, are blessed with abundant local materials of good qual-
ity which, being neither resilient nor frost-susceptible, have
performed well on other projects. In such areas this type of
foundation construction may be the most logical choice.
Specifications for such materials should require a reasonable
gradation cohesionless sands are undesirableand a degree of
stability equivalent to a CBR value of around 20 or more in
a soaked condition. Good drainability is desirable, but too
open a texture may not be a wise choice unless positive out-
lets are provided at frequent intervals for the removal of free
water which might otherwise soften the underlying soil.
Crushed Stone Subbase
More reliable granular subbases have been built of crushed
stone on extensive sections of the interstate and primary sys-
tems in states such as Virginia and Connecticut. Materials for
this purpose may have a variety of gradations, usually open
and free draining, with top sizes preferably in the 2 to 3 inch
range (See Figure 2). Such large particles, keyed together
and confined by denser layers above, permit the attainment
of extremely high stability. The same precautions noted
above must be followed with respect to provision of positive
* See Appendix B
3
outlets for drainage. Too open a gradation may also invite in-
filtration of soil fines from beneath.
-
:
Jc
-
7'---S-
' Sr
s '-
-.'
C. -
ur 2
C ar e Open Graded Crus her Run Stone of
a Type
Suited for Subbase Construction.
Subgrade or Subbase Stabilization
A third method of foundation improvement is available
through chemical stabilization of the native soils, usually with
cement or hydrated lime. Cement is more suitable in friable
soils where mixing and compacting may be most easily ac-
complished; 6 to 10 percent cement by weight is most gener-
ally specified. Lime, which reacts more slowly, is more effec-
tive in cohesive soils which are not easily pulverized. Either
method, where it can be successfully carried out, is extremely
effective in killing the plasticity, resiliency, and frost suscep-
4
tibility of the native soil and in providing a stable working
platform on which to construct subsequent layers.
On some projects, preference should be given to chem-
ical stabilization in the granular subbase rather than in the na-
tive soil. Here a reasonably uniform aggregate material such
as stone screenings or crusher run, which may be too high in
fines for the more usual free draining subbase, is stabilized by
the addition of 4 or 5
percent cement. Such a mixture usu-
ally makes a truly superior foundation course for the layers
above and greatly reduces the load stresses on the soil be-
neath. Being relatively impervious, it is not so necessary that
these stabilized subbases be drained.
It is the nature of any cement stabilized soil or aggregate
mixture to develop shrinkage cracks. It is important therefore
that the base material above such foundations be of a type
that will absorb these cracks rather than reflect them through
to the surface.
The choice of method of foundation construction de-
pends upon types of soils in the grade, the availability of ma-
terials in the area, and the depth of probable frost penetra-
tion. Again it is emphasized that only in rare cases may foun-
dation construction be ignored.
THE BASE COURSE - WHERE CRUSHED
-STONE IS THE IDEAL CHOICE
As already noted, attempts to use rigid or semi-rigid
bases for flexible pavements often produce undesirable re-
sults. Concrete base slabs must have joints or else they will
develop cracks; either the joints or the cracks will reflect
through bituminous surfacings, creating maintenance prob-
lems as well as an unsightly condition. (See Figure 3)
Soil cement or cement treated aggregates, although quite
successfully used in many areas as
subbases,
often create the
same sort of problems when used as bases (See Figure 4).
Even hot mixed asphaltic bases may tend to develop cracks
which are reflected through successive resurfacings, particu-
larly where local bank run aggregates are used in poorly de-
signed mixes. (See Figure
5)
-.--t--- ----
-.. .&r_4,
1
4
Figure 3. Cracks Reflected Through
4 Inches of As phaltic Concrete from
Joints )background) and Random
Cracks )foreground) in a Portland Ce-
ment Concrete Bas e.
Figure 4. Cracks Reflected Through
2'/ Inches of Hot Mixed Sand As phalt
from a Soil Cement Bas e.
_
----=--
AT
Figure 5. Hot Mixed Sand As phalt Us ed as Bas e and Surface 7-inch total thick-
nes s ) on Lightly Traveled Highway is Badly Cracked. Attempts to Fill Cracks and
Seal Surface Uns ucces s ful.
6
The ideal material for use as a base for flexible pavement
is quality controlled, dense graded crushed stone. Properly
graded, compacted, and supported by an adequate founda-
tion, dense graded stone possesses all the attributes required
of a base course. Through internal friction between its parti-
cles, it resists lateral displacement and further densification
under traffic. Thus it normally needs no cementitious addi-
tives and so should not develop shrinkage or fatigue cracks.
Research at the laboratory of the National Crushed
Stone Association has determined that the following are the
most desirable characteristics of a graded aggregate base:
The grading should be continuous from the maxi-
mum size down to and including the dust of frac-
ture.
2. The maximum size of aggregate should be the larg-
est that can be handled without segregation.
3. The quantity passing No. 200 sieve should be be-
tween 5 and 12 percent and not over 10 percent
where frost penetration may be a problem. Even
lower percentages are preferable.
4. The plasticity index should be kept as low as pos-
sible: non-plastic fines are the best.
5. The aggregate should be compacted to the maxi-
mum density attainable, preferably not less than
100 percent of AASHO T-180(ASTM D 1557).
6. The aggregate should consist of crushed stone
throughout the size range to assure the highest
strength and greatest rigidity.
(See NCSA Engineering Bulletin No. 12-Characteristics of
Graded Base Course Aggregates Determined by Triaxial Tests
available from the Association's Washington office.)
7
It is emphasized that the grading should be uniform,
from a maximum size as large as can be handled properly
down to and including a closely controlled percentage of non-
plastic fines. The actual percentage passing one of the inter-
mediate sieve sizes is not as important as is the fact that this
percentage should not vary widely from load to load. Varia-
bility, even within permissible ranges, is undesirable for sever-
al reasons, but principally on account of the effect produced
on the density to which the material can be compacted and
on the moisture content needed to obtain this density. The
maximum density in standard tests like AASHO T- 180 varies
appreciably as the percentages of coarse and fine aggregate
vary. (For a more complete explanation of compaction con-
trol of graded aggregates, see Nichols' paper in Highway Re-
search Board Bulletin 325.)
Research by NCSA has also shown that an increase of
only six pounds per cubic foot in the density of a given aggre-
gate mixture can increase its shearing resistance in the CBR
test around 21/2 times, further emphasizing the importance of
compaction control on base materials. The importance of ad-
equate and uniform compaction cannot be overemphasized.
Achievement of this goal is facilitated by good construction
techniques which minimize segregation during laydown. (See
Figure 6)
Figure 6. Proper Equipment for Handling and Spreading Aids in Ob-
taining Uniform Density and Minimizes Segregation.
8
Specifications for the materials and methods of con-
struction required for a high class crushed aggregate base
course should contain paragraphs similar to those suggested
in Appendix A. The materials specifications, while permitting
a variety of gradations--and consequently maximum econ-
omy of productionemphasize the importance of uniformity
of gradation from truckload to truckload. This important at-
tribute is seldom present in naturally occurring deposits, and
can be assured only by the careful quality control exercised
by reputable commercial producers. It will be noted that
these specifications have a great deal to say about how the
materials are to be blended, sampled, and tested at the source,
hauled to the job, spread, and compacted.
A further note is appropriate for the designer of pave-
ments to be subjected to deep frost penetration. For such
service, the base material's job mix formula should be estab-
lished toward the lower limit of the range with regard to the
amount passing the 200 mesh sieve. If this requirement can-
not be met by the local producers, it may be found necessary
to incorporate an appropriate stabilizing admixture to render
the minus 200 material innocuous Emulsified asphalt, port-
land cement, and lime-fly ash have all been used with success
where proper attention has been given to the necessary curing
conditions.
As noted earlier, stabilization should not be resorted to
as a substitute for compaction or for the purpose of making
the base strong enough to bridge over weak spots in the foun-
dation. The addition of more than two or three percent ce-
ment, by weight, may cause shrinkage cracking and make the
base brittle. Admixtures to a stone base material should be
for the sole purpose of altering the character of the fines to
maintain the mixture's inherent stability under all weather
conditions.
Finally, the importance of achieving the maximum den-
sity practicable for the grading selected for the job is again
emphasized. It is not the value of density, per Se, that is im-
9
portant; higher density values can often be obtained by in-
creasing the percentage of fines, but this may create other un-
desired effects. The important point is that the material
placed in the road be compacted so that little or no addition-
al densification can possibly occur under traffic. This may be
accomplished more easily with the addition of a very small
percentage of calcium chloride, which may provide the added
advantage of combatting potential frost susceptibility.
THE BITUMINOUS MAT
The choice of the type and thickness of the bituminous
mat to be used depends upon a number of factors. For
less important rural highways and other locations where traf-
fic volumes are apt to be light, there is often a great advantage
to be gained through the use of stage construction, by which
a temporary or semi-permanent wearing surface is applied as
part of initial construction and a final surfacing is programmed
for later application when needed. Under this system, the
temporary surfacing should possess a high degree of flexibility
to withstand the relatively high deflections which may occur
early in the pavement's life. Various types of bituminous sur-
face treatment have been used successfully as temporary rid-
ing surfaces.
Where heavier traffic is expected and where superior rid-
ing quality is deemed essential, a bituminous concrete mat is
generally called for. Standard state highway specifications
are usually the best guide to suitable mixtures for this pur-
pose in a given area. Suitable mixes are also defined under
ASTM Standard Specification D 1663 for Hot-Mixed, Hot-
Laid Asphalt Paving Mixtures. Although other types of ag-
gregate have been used successfully in some bituminous
mixes, crushed stone meeting the quality requirements of
ASTM Standard Specification D 692 truly sets the standard
of excellence for this purpose.
10
On a base and foundation constructed in accordance
with this guide, a thickness of bituminous concrete of from
four to six inches is most highly recommended. The lower
portion of this thickness is usually termed the binder, and
should contain stone with a top size of
3/4
inch or somewhat
larger. The upper l'/4to l'/2 inch wearing surface mix gener-
ally does not contain aggregate as large as
3/4
inch, but a top
size smaller than inch is not recommended. Finer mixes are
often considerably less durable and develop fatigue cracks at
an early age. In addition, although some fine mixes have high
skid resistance at low speeds, heavy downpours often pro-
duce water films thick enough to cause vehicles to "hydro-
plane," causing complete loss of steering control. Coarser
mixes tend to break this water film and minimize the prob-
lem.
THICKNESSES OF THE BASE AND BITUMINOUS MAT
If the designer has assured himself that a permanently
firm, non-resilient subgrade or subbase will be provided as a
foundation, the question of thickness of the crushed stone
base and bituminous mat becomes relatively simple. Recall
though that the key to this relative simplicity is the assump-
tion that the foundation can be relied on to provide support
equivalent to a CBR value of 20 at all times and under all con-
ditions. The total thickness required above this foundation
can 'be estimated from design curves devised by the Corps of
Engineers and many other agencies. To add a factor of safety
without adding unduly to the cost, the designs may be se-
lected to satisfy a slightly lower CBR, say, 15.
Depending only upon the volume and weight of traffic
expected, the total thickness of base and bituminous mat re-
quired over a CBR of 15 might vary from 7 to 15 inches. As
an additional factor of safety to account for ever increasing
wheel loads and tire pressures, the table of standard designs
presented below includes total thicknesses of from 8 to 18
inches.
Er
The table of designs just referred to gives thicknesses in
terms of five categories of traffic. Traffic counts ordinarily
are made in terms of the average daily volume of (a) automo-
biles and pickups, (b) light commercial vehicles like package
haulers, (c) more heavily loaded vehicles like dump trucks,
and (d) trailer trucks and large buses. For design purposes,
however, it is generally necessary to consider only the heavier
vehicles of designations (c) and (d).
A typical design table for use where crushed stone aggre-
gates meeting the specifications of Appendix A are available
for the base course is presented next:
Table 1
Standard Designs for Construction on a Non-Resilient
Foundation With a Support Value Equivalent to CBR 20
Thickness of High
Type Bituminous
Mat
Traffic Category1
IIIIIIIV
21/2Y
1.,,
V
6"
Thickness of Well
Compacted Dense
Graded Stone Base6"8"
8210 2 122
Note 1. Definition of Traffic Categories:
Number Average Daily Volume of Heavy Trucks
and Buses in One Direction
0-15
II
16-50
III
51-200
IV
201-800
V