During the last two decades, environmental awareness and climate change concerns have encouraged and supported the implementation of recycled techniques in the Transportation Infrastructure Industry for rehabilitating and constructing pavements in the United States. Besides that, pavement roads are public goods that bring economic and social benefits to all countries. Therefore, assessing the pavement structural condition is essential to understand the performance of new materials and determine actions for conservation, maintenance, or rehabilitation. In-situ Pavement monitoring through embedded instrumentation is a type of monitoring technique, which uses several sensors installed within the pavement to obtain the structural responses used in Mechanical-Empirical design to control the performance and define asset management plans. This thesis presents the instrumented response of a Recycled Pavement Section on the Interstate 64 (located in Virginia, USA) to analyze the actual pavement responses (strain and stress) under real traffic and environmental conditions. Several sensors were installed during the construction (including strain gauges, pressure cells, thermocouples, and TDR probes), and two recycling techniques were used (CCPR and Full Depth Reclamation (FDR)) in this project. The Instrumented Recycled Pavement Section analyzed in this research was tested during five months in 2019 to evaluate the effect of temperature, sensor location, and load configuration on the pavement responses collected in the field. During the tests, three loaded trucks ran over the instrumented section. The results showed that the pavement structure is working properly, the stress responses decreased with depth, the maximum strain over the months was compared, and the temperature effect was addressed. Nevertheless, the stress and strain data obtained in each test presented a large variability because it is difficult to control the position where the trucks are passing during this type of experiment. Furthermore, the measured strains were useful to develop a calibrated pavement structural model, which showed that the pavement is expected to have a long structural service life. / M.S. / During the last two decades, different Departments of Transportation have been studying the implementation of recycled materials in pavement structure to provide better economic, environmental, and social benefits by addressing environmental challenges within the Transportation Infrastructure Industry. Among the emerging recycled techniques, Cold-Central Plant Recycling (CCPR) and Full Depth Reclamation (FDR) are included. Both procedures recollect and use the existing asphalt in the rehabilitation or reconstruction of the new pavement structure. The main benefits of pavement recycled materials include reduction of raw materials required and gas emissions. Nevertheless, recycled techniques are not commonly implemented due to the lack of information about long-term performance under real traffic and environmental conditions. In addition, since 2004, when the new Pavement Design Guide was released, the evaluation and validation of new materials require the understanding of the interaction between material properties, traffic, and climate. To address this concern, this thesis analyzed the pavement response measurements obtained in the Interstate 64 Widening Project (Virginia, USA), where two recycling techniques were used (CCPR and FDR). In this project, several sensors were installed during the construction to obtain information regarding the current environment condition (temperature and moisture) and pavement performance (stress and strain). The recycled pavement section was tested during five months of 2019 and trucks with known load configurations were implemented in the field tests. The results showed that the pavement structure is properly working, there is an acceptable stress distribution within the pavement layers, and the overall thickness is expected to have a long structural service life. Besides that, measured strain values obtained through the field experiment were compared with the theoretical ones obtained with computational tools.

Cold Central Plant Recycling (CCPR) has been used by many state highway agencies to save material, money, time, and energy in pavement construction and rehabilitation. The objectives of this thesis were to: (1) perform an instrumented verification analysis, (2) evaluate the response and performance of two pavement configurations with a CCPR base layer through accelerated pavement testing (APT), and (3) construct models using mechanistic-empirical pavement design software for comparison with the APT results. The pavement configurations featured a 5-inch CCPR mixture with either a 3-inch or 1.5-inch SM-9.5D surface mixture. Each section was instrumented with strain gauges, pressure cells, and thermocouples. A heavy vehicle simulator (HVS) was used to load three replicate test sections in each lane, with the temperature controlled at 39°C at a depth of 1.5 inches. Results from the instrument verification analysis showed that the strain gauges and pressure cells used in the experiment recorded pavement responses with a high degree of repeatability. In addition, the loading condition variables (speed, wheel load, and tire inflation pressure) affected the response following the expected trends and did not affect the repeatability of the instruments. The average CV of all strain gauge and pressure cell signals was approximately 0.009 or 0.9%, and 0.004 or 0.4%, respectively. In terms of the rutting comparison, the sections with the 3-inch surface layer outperformed the sections with the thinner 1.5-inch surface layer. However, the age of the pavement at the start of testing significantly affected the rutting performance. After adjusting for the pavement age at the time of testing, the section with the thicker surface showed approximately half of the rutting of the section with the thinner surface. The results from preliminary ME Design analysis indicate that the software cannot model the studied APT sections using the default material properties and calibration factors available at the time of analysis. In particular, the software does not seem to be prepared to model the CCPR materials. / Master of Science / Accelerated Pavement Testing (APT) is a useful method for evaluating pavements, validating instrument responses, and developing pavement models. The APT uses a Heavy Vehicle Simulator (HVS) as a loading mechanism to simulate the effects of truck traffic on pavement sections. Strain gauges and pressure cells are installed in the pavement sections to monitor the pavement performance and record key points of strain and pressure. This thesis contains the findings and results of APT testing on two sections of pavement containing a cold central plant recycled (CCPR) base mixture; one section has a 3 inch surface mixture while the other has a 1.5 inch surface mixture. Also, an instrument verification exercise is conducted, and an ME Design model is constructed for comparison with the rutting results of the APT testing. Results from the instrument verification analysis showed that the strain gauges and pressure cells used in the experiment recorded pavement responses with a high degree of repeatability. In addition, the loading condition variables (speed, wheel load, and tire inflation pressure) affected the response following the expected trends and did not affect the repeatability of the instruments. In terms of the rutting comparison, the sections with the 3-inch surface layer outperformed the sections with the thinner 1.5-inch surface layer. However, the age of the pavement at the start of testing significantly affected the rutting performance. After adjusting for the pavement age at the time of testing, the section with the thicker surface showed approximately half of the rutting of the section with the thinner surface. The results from ME Design model indicate that the software cannot model the studied APT sections using the default material properties and calibration factors available at the time of analysis. In particular, the software does not seem to be prepared to model the CCPR materials.

In-service pavements require maintenance and rehabilitation (MandR) interventions to keep them in compliance with structural and functional standards. With the increased focus on the sustainability of our roadway systems, it has become important to document the cost and environmental impacts of different MandR strategies over the life cycle of the pavement to facilitate project selection decisions in the future. Asphalt pavement recycling, while cost-effective and environmentally friendly compared to other traditional MandR treatments, still faces some widespread implementation push-back, leading to policy enactments by the FHWA aimed at encouraging the use of recycling in road projects. Many agencies and contractors have cited the lack of project selection criteria, and uncertainty about long-term performance of these recycling alternatives as reasons impeding rapid implementation of these treatments in road projects. One of the gray areas of the FHWA's 2015 Recycled Material Policy in project selection was, until recently, the lack of guidelines or tools for the assessment of the environmental suitability of candidate MandR treatments. Today, it is almost impossible to evaluate the environmental suitability of various recycling-based end-of-service-life treatments because available databases do not have relevant information on the details of unit processes, construction equipment and activities, and use-stage roughness data. Development of future MandR plans throughout the service life of pavements rehabilitated with recycling-based treatments is somewhat limited as deterioration is not fully understood. Also, available modeling tools no not address all LCA phases, or in cases where they do, key life cycle phases including the MandR, and use phases are not well covered due to the lack of quantification highlighted earlier. To address the highlighted concerns, this dissertation developed a user-friendly comprehensive LCA tool that was further validated with a case study to quantify the service life (when the pavement has reached a critical threshold performance value) and potential environmental benefits of pavement recycling projects executed by the Virginia Department of Transportation over the past decade. The tool, pySuPave, includes an excel spreadsheet user-inputs interface, and database of economic flows for unit processes used in the production of pavement materials and subsequent construction of the pavement system, considering transportation of materials and construction machinery to plants and construction site. A python-based program was used to perform matrix-based computations to generate the environmental burdens from the available public LCA Ecoinvent database. A substantive part of the dissertation was dedicated to evaluating the performance of in-service pavements rehabilitated with cold recycling and full-depth reclamation treatments, focusing on developing pavement performance prediction models (PPPM) that goes on to improve modelling of the MandR and use stages in the pavement LCA and ultimately bridges the knowledge gap on how these treatments perform in the long term. This part of the dissertation was presented in two chapters; trends in pavement recycling and performance data collection, and development of PPPMs for recycled asphalt pavements. The first provides an update and examines the current state of pavement recycling techniques, highlighting trends in the various recycling methods, examining what is and is not working from the agency perspective, and assessing the progress made in the last decade through a web-based survey. The survey results did not indicate significant changes in the adoption of the asphalt pavement recycling concept in the last decade. However, recycling techniques, such as hot in-place recycling, are being used less and more agencies seem to be adopting lower temperature techniques such as cold in-place recycling, cold central plant recycling and full depth reclamation. Improvements in mix design methods were noticeable, as more agencies have adopted contemporary methods, such as the Superpave design. Among states, very few agencies collected performance data for completed asphalt pavement recycling projects. The second chapter on performance focused on developing individual and family-type PPPMs from the data collected from the states of Virginia and Colorado, respectively. While regression modeling forms the backbone of the approach used, the chapter also presents an approach to developing family-type models using functional data analysis to find groups of projects with similar deterioration trends. In the case of Colorado, cold in-place recycling (CIR) projects completed with an initial IRI between 71 and 91 in/mi are most likely to deteriorate at an average group rate of 1.37 in/mi/year. Similarly, full depth reclamation (FDR) projects will most likely deteriorate following an average group rate of 1.40 in/mi/yr, with an initial IRI between 52 and 70 in/mi. These projects will stay in service well over 30 years if a threshold IRI of 140 in/mi were used a failure criterion. For the individual roughness models developed for VDOT, the initial IRI values and the rate of change for the treatments analyzed were found to range between 48 and 85 in/mi and between 0.70 and 5.20 in/mi/year, respectively, depending on the recycling method and type of stabilization treatment. Finally, a context-based life cycle assessment case study was conducted to benchmark and compare the environmental impacts associated with rehabilitating a low-volume road with various recycled-based and equivalent conventional methods. Several impact indicators were assessed but only the global warming (GW) score and the single score index that combines all the environmental impact indicators into a single number using normalization and weighting factors were reported in this study for the sake of brevity. Four restorative maintenance projects including two CIR (4-in. HMA over a 5-in. CIR with foamed asphalt and emulsion stabilization), one cold central plant recycling (CCPR): 4-in. HMA over a 5-in. foamed asphalt CCPR (CCPR FA), and one non-recycling structural overlay (8-in. HMA over an existing pavement) were evaluated. In addition, the following reconstruction projects were assessed; two FDR (4-in. HMA over a 12-in. FDR with foamed asphalt with 1% cement additive, and a 4-in. HMA over 10.5-in. cement stabilized FDR), and a non-recycling reconstruction project (a new reconstruction project with 8-in. HMA over a 16-in. aggregate base and subbase). The functional unit was a two lane-mile length, 12 feet wide project with a traffic volume of 1000 vehicles (3% trucks) and the analysis was conducted for 50 years. The GW score and a few other impact indicators showed an increase in the observed results where cement is used as a main stabilizer or as an additive. Between the asphalt stabilized projects, the difference in impact scores is only seen when cement is used as an additive as highlighted in the case of foamed asphalt applications. Even for the low-volume road under study, the use stage contributes the largest share to global warming and is—among several factors—attributed to the initial surface roughness of completed projects. Thus, for state DOTs looking to reduce the environmental footprints for road infrastructure projects and achieve federal legislative goals, building smoother roads and taking steps to keep the annual deterioration rate low would be an important measure, in addition to pavement recycling. Comparing the projects based on the overall single score derived from weighting factors from the National Institute of Standards and Technology (NIST) ranks the projects as follows (listed in order decreasing impacts per rehabilitation category); restorative maintenance projects: T. OVERLAY (non-recycling structural overlay—8 in. HMA over an existing pavement) - 1.06 pts, CCPR FA (4 in. HMA over a 5 in. cold central plant recycling with foamed asphalt) - 1.02 pts, CIR FA (4 in. HMA over a 5 in. cold in-place recycling with foamed asphalt) - 1.00 pts, CIR AE (4 in. HMA over a 5 in. cold in-place recycling with emulsion)- 0.86 pts; reconstruction projects: RECONS (a new reconstruction project—8 in. HMA over a 16 in. aggregate base and subbase) -1.42 pts, FDR FA+C (4 in. HMA over a 12 in. FDR with foamed asphalt with 1% cement additive) - 1.15 pts, FDR C (4 in. HMA over 10.5 in. cement stabilized FDR) - 1.02 pts. / Doctor of Philosophy / Due to harsh environmental conditions and continual damage from moving traffic, highway pavements or roadways deteriorate and grow weak over time. Throughout their life in service, different maintenance and rehabilitation (MandR) activities are performed with the intention of slowing down the deterioration to always keep the highway at a certain level of service to road users. For a long time, these MandR activities have included the use of virgin materials in techniques ranging from minor treatment applications such as fog seals, chip seals, thin overlays through more heavy treatments such as mill and fills, thicker overlays all the way to total reconstruction. Other MandR alternatives include pavement recycling which reuses materials from the existing distressed roadways either in-place or at a nearby mobile plant have gained popularity among several state highway agencies over the last decade. The advantages of using the recycling alternatives compared to non-recycling options are many and have been known to include cost savings, less construction time, and low environmental footprint. Many highway agencies, however, have expressed the lack of information on project selection criteria and the uncertainty about long-term performance of these recycling alternatives as reasons impeding rapid and widespread implementation in road projects. Agencies need selection criteria to help them identify the right treatments to apply to the right road at the right time. In a bid to encourage the use of pavement recycling treatments, the Federal Highway Administration (FHWA) enacted the Recycled Materials Policy in 2006 (revised 2015) but the policy did not fully address certain aspects of project selection. Directives on assessing the environmental suitability of recycling projects, for instance, was not given. There are no tools with modern databases incorporating the various unit processes for pavement recycling to aid agencies carry out this environmental assessment. To address the highlighted concerns, we developed a user-friendly comprehensive environmental assessment tool called pySuPave as part of this dissertation. We later validated the tool with a case study to quantify the potential environmental benefits of pavement recycling projects executed by the Virginia Department of Transportation over the past decade. Next, we conducted a survey of the departments of transportation (DOT) around the United States and Canada to collect performance data from agencies with active in-place recycling programs. Approximately 18% of the DOTs surveyed were able to provide performance data. Data received from Colorado and Virginia were subsequently used to developed models to predict deterioration in recycled pavements. In the case of Colorado, CIR projects completed with an initial roughness (IRI) between 71 and 91 in/mi are most likely to deteriorate at a rate of 1.37 in/mi/year. Similarly, FDR projects will most likely deteriorate following an average group rate of 1.40 in/mi/yr, with an initial IRI between 52 and 70 in/mi. These projects will stay in service well over 30 years if a threshold IRI of 140 in/mi were used a failure criterion. For the individual roughness models developed for VDOT, the initial IRI values and the rate of change for the treatments analyzed were found to range between 48 and 85 in/mi and between 0.70 and 5.20 in/mi/year, respectively, depending on the recycling method and type of stabilization treatment Finally, we conducted an environmental assessment case study to benchmark and compare the environmental burdens i.e., global warming (GW) and other impacts associated with rehabilitating a low-volume road with various recycled-based and equivalent non-recycling methods. Four restorative maintenance projects including two CIR (4-in. HMA over a 5-in. CIR with foamed asphalt and emulsion stabilization), one CCPR (4-in. HMA over a 5-in. foamed asphalt CCPR [CCPR FA]), and one non-recycling structural overlay (8-in. HMA over an existing pavement) were evaluate. In addition, the following reconstruction projects were assessed; two FDR (4-in. HMA over a 12-in. FDR with foamed asphalt with 1% cement additive, and a 4-in. HMA over 10.5-in. cement stabilized FDR), and a non-recycling reconstruction project (a new reconstruction project with 8-in. HMA over a 16-in. aggregate base and subbase). The functional unit was a two lane-mile length, 12 feet wide project with a traffic volume of 1000 vehicles (3% trucks) and the analysis was conducted for 50 years. The study results showed that the recycling-based projects had lower overall environmental burdens compared to their equivalent non-recycling alternatives. The GW score and a few other environmental impact indicators were higher when cement is used as a main stabilizer or as an additive in the recycling projects. Between the asphalt stabilized recycling projects, the difference in impact scores is only seen when cement is used as an additive as emphasized in the case of foamed asphalt applications. Even for the low-volume roads under study, the use stage (when the project is open to road-users) in the pavement life cycle contributes the largest share to global warming and is—among several factors—attributed to the initial surface roughness of completed projects. Thus, for state DOTs looking to reduce the environmental footprints for road infrastructure projects and achieve federal legislative goals, building smoother roads and taking steps to keep the annual deterioration rate low would be an important measure, in addition to pavement recycling. The results from this research support the hypothesis that pavement recycling can reduce global warming and other environmental burdens compared to non-recycling methods. Therefore, agencies should encourage more pavement recycling programs.