An inverted base pavement is a new pavement structure that consists of an unbound aggregate base between a stiff cement-treated foundation layer and a thin asphalt cover. Unlike conventional pavements which rely on upper stiff layers to bear and spread traffic loads, the unbound aggregate inter-layer in an inverted base pavement plays a major role in the mechanical response of the pavement structure. Traditional empirical pavement design methods rely on rules developed through long-term experience with conventional flexible or rigid pavement structures. The boundaries imposed on the unbound aggregate base in an inverted pavement structure change radically from those in conventional pavements. Therefore, current empirically derived design methods are unsuitable for the analysis of inverted base pavements. The present work documents a comprehensive experimental study on a full-scale inverted pavement test section built near LaGrange, Georgia. A detailed description of the mechanical behavior of the test section before, during and after construction provides critically needed understanding of the internal behavior and macro-scale performance of this pavement structure. Given the critical role of the unbound aggregate base and its proximity to the surface, a new field test was developed to characterize the stress-dependent stiffness of the as-built layer. A complementary numerical study that incorporates state-of-the-art concepts in constitutive modeling of unbound aggregates is used to analyze experimental results and to develop preliminary guidelines for inverted base pavement design. Simulation results show that an inverted pavement can deliver superior rutting resistance compared to a conventional flexible pavement structure with the same fatigue life. Furthermore, results show that an inverted base pavement structure can exceed the structural capacity of conventional flexible pavement designs for three typical road types both in rutting and fatigue while saving up to 40% of the initial construction costs.

The current economic situation has severely affected the US road infrastructure and funding has become inadequate for either maintenance or future growth. The inverted base pavement structure is a promising alternative to achieve high quality roads at considerably lower cost than conventional pavements. The proximity of the unbound granular base layer to the tire load makes the response of the granular base critical to the performance of the pavement structure. Therefore extensive material characterization is conducted on the granular materials that make the base. In particular, a true triaxial chamber is developed to study the mechanical response and the stress-dependent stiffness of granular bases compacted at different water contents. A novel method is developed to assess the as-built stress-dependent anisotropic stiffness of granular bases in-situ using both crosshole and uphole test configurations. The two inverted base pavements built in Georgia at the Morgan County quarry haul road and the Lagrange south Loop are tested as part of this study. A nonlinear orthotropic constitutive model is selected to capture the deformational behavior of compacted granular bases. The response of the pavement is analyzed by implementing this constitutive behavior in a three-dimensional finite-element model. Different pavement structures are simulated. It is shown that thin asphalt concrete layers resting directly on granular bases deform as membranes. Finally, numerical simulations are extended to compare inverted base pavements to conventional pavements used in practice. Results highlight the inadequacy of ASSHTO’s structural layer coefficient for the analysis of inverted base pavement structures as well as the potential economic advantages of inverted base pavements.