Effects of Interlayer Systems on Reflective Cracking in Unbonded Overlays of Existing Concrete Pavements

Reflective cracking can be a concern in unbonded concrete overlays of existing distressed concrete pavements. In these structures, an interlayer, commonly hot-mix asphalt (HMA) or a nonwoven geotextile fabric, is placed to isolate the overlay concrete from the existing concrete pavement. The interlayer minimizes interaction between the overlay and the existing concrete pavement, which helps prevent distress in the existing pavement from propagating into the overlay. In this study, a laboratory investigation was used to examine the influence of HMA and geotextile fabric interlayer systems on the potential for development of reflective cracking. A laboratory test was conducted by using stacked beam specimens separated by an interlayer to evaluate the potential for a discrete crack in the lower beam reflecting up through the interlayer and into the overlay beam. The study revealed that reflective cracking was more likely when there was loss of support beneath the existing pavement. Reflective cracking did not occur with any of the interlayer systems when the beam was fully supported. The nonwoven geotextile interlayers that were tested were more effective than the HMA interlayers at preventing reflective cracking. Even though the fabric interlayer had a higher load ratio than the HMA interlayers, a relatively large load was required to generate reflective cracking regardless of the interlayer type (HMA or fabric) and, therefore, both may be suitable interlayer alternatives for the prevention of reflective cracking.