Virgin aggregate is being used faster than it is being made available creating a foreseeable shortage in the future. Despite this trend, the availability of demolished concrete for use as recycled concrete aggregate (RCA) is increasing. Using this waste concrete as RCA conserves virgin aggregate, reduces the impact on landfills, decreases energy consumption and can provide cost savings. However, there are still many unanswered questions on the beneficial use of RCA in concrete pavements. This research addresses the many technical and cost-effective concerns regarding the use of RCA in concrete pavements by identifying concrete mixture and proportioning designs suitable for jointed plain concrete pavements; constructing test sections using varying amounts of RCA; monitoring performance through testing, condition surveys and sensor data; modeling RCA pavement performance; and predicting life cycle costs. The research was carried out as a partnership between the Centre for Pavement and Transportation Technology (CPATT) at the University of Waterloo, the Cement Association of Canada, Dufferin Construction, and the Natural Sciences and Engineering Research Council of Canada. The literature review provides an overview of sustainability and key performance indicators, the material properties of RCA both as an aggregate and in concrete, concrete mixture and proportioning designs with RCA, performance of existing RCA pavements, and the implementation of RCA highlighting some examples where RCA has been used successfully. Twelve preliminary mixes were developed using three total cementitious contents amounts of 315 kg/m3, 330 kg/m3, and 345 kg/m3 to determine four suitable mixes with varying coarse RCA contents (0%, 15%, 30% and 50%) to place at the CPATT test track. At 28-days, all of the twelve mixes exceed the 30 MPa design strength. Four test sections containing 0%, 15%, 30% and 50% coarse RCA were constructed in June 2007. The test sections had identical cross sections consisting of 250 mm portland cement concrete (PCC), 100 mm asphalt-stabilized OGDL and a 450 mm granular base. For each coarse RCA content, one slab was instrumented with six vibrating wire concrete embedment strain gages to measure long-term longitudinal and transverse strain due to environmental changes, two vibrating wire vertical extensometers to monitor slab curling and warping, two vibrating wire inter-panel extensometers to monitor joint movement, and two maturity meters to measure maturity and temperature. Quality assurance and quality control (QA/QC) testing showed that the mixes containing RCA exhibited similar or improved performance when compared to the conventional concrete for compressive and flexural strength, freeze-thaw durability and coefficient of thermal expansion. Pavement performance of the four test sections was evaluated using visual surveys following the Ontario Ministry of Transportation’s Manual for Condition rating of Rigid Pavements. Nine pavement evaluations have been performed every two to four months since construction. All test sections are in excellent condition with pavement condition index (PCI) values greater than 85 after two years in-service and approximately three hundred thousand Equivalent Single Axle Loads. Sensor data from the strain gauges, and vertical and inter-panel extensometers are providing consistent results between the test sections. Long-term performance modeling using the Mechanistic-Empirical Pavement Design Guide (ME-PDG) showed improved performance with respect to cracked slabs, joint faulting, and pavement roughness as the RCA content increased. Multivariable sensitivity analysis showed that the performance results were sensitive to CTE, unit weight, joint spacing, edge support, surface absorption, and dowel bar diameter. Life cycle cost analysis (LCCA) illustrated the savings that can be expected using RCA as a replacement aggregate source as the cost of virgin aggregate increase as the sources becomes depleted. Multivariable sensitivity analysis showed that the LCCA results were sensitive to construction costs, discount rate, and maintenance and rehabilitation quantities.

Virgin aggregate is being used faster than it is being made available creating a foreseeable shortage in the future. Despite this trend, the availability of demolished concrete for use as recycled concrete aggregate (RCA) is increasing. Using this waste concrete as RCA conserves virgin aggregate, reduces the impact on landfills, decreases energy consumption and can provide cost savings. However, there are still many unanswered questions on the beneficial use of RCA in concrete pavements. This research addresses the many technical and cost-effective concerns regarding the use of RCA in concrete pavements by identifying concrete mixture and proportioning designs suitable for jointed plain concrete pavements; constructing test sections using varying amounts of RCA; monitoring performance through testing, condition surveys and sensor data; modeling RCA pavement performance; and predicting life cycle costs. The research was carried out as a partnership between the Centre for Pavement and Transportation Technology (CPATT) at the University of Waterloo, the Cement Association of Canada, Dufferin Construction, and the Natural Sciences and Engineering Research Council of Canada. The literature review provides an overview of sustainability and key performance indicators, the material properties of RCA both as an aggregate and in concrete, concrete mixture and proportioning designs with RCA, performance of existing RCA pavements, and the implementation of RCA highlighting some examples where RCA has been used successfully. Twelve preliminary mixes were developed using three total cementitious contents amounts of 315 kg/m3, 330 kg/m3, and 345 kg/m3 to determine four suitable mixes with varying coarse RCA contents (0%, 15%, 30% and 50%) to place at the CPATT test track. At 28-days, all of the twelve mixes exceed the 30 MPa design strength. Four test sections containing 0%, 15%, 30% and 50% coarse RCA were constructed in June 2007. The test sections had identical cross sections consisting of 250 mm portland cement concrete (PCC), 100 mm asphalt-stabilized OGDL and a 450 mm granular base. For each coarse RCA content, one slab was instrumented with six vibrating wire concrete embedment strain gages to measure long-term longitudinal and transverse strain due to environmental changes, two vibrating wire vertical extensometers to monitor slab curling and warping, two vibrating wire inter-panel extensometers to monitor joint movement, and two maturity meters to measure maturity and temperature. Quality assurance and quality control (QA/QC) testing showed that the mixes containing RCA exhibited similar or improved performance when compared to the conventional concrete for compressive and flexural strength, freeze-thaw durability and coefficient of thermal expansion. Pavement performance of the four test sections was evaluated using visual surveys following the Ontario Ministry of Transportation’s Manual for Condition rating of Rigid Pavements. Nine pavement evaluations have been performed every two to four months since construction. All test sections are in excellent condition with pavement condition index (PCI) values greater than 85 after two years in-service and approximately three hundred thousand Equivalent Single Axle Loads. Sensor data from the strain gauges, and vertical and inter-panel extensometers are providing consistent results between the test sections. Long-term performance modeling using the Mechanistic-Empirical Pavement Design Guide (ME-PDG) showed improved performance with respect to cracked slabs, joint faulting, and pavement roughness as the RCA content increased. Multivariable sensitivity analysis showed that the performance results were sensitive to CTE, unit weight, joint spacing, edge support, surface absorption, and dowel bar diameter. Life cycle cost analysis (LCCA) illustrated the savings that can be expected using RCA as a replacement aggregate source as the cost of virgin aggregate increase as the sources becomes depleted. Multivariable sensitivity analysis showed that the LCCA results were sensitive to construction costs, discount rate, and maintenance and rehabilitation quantities.

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Stochastic analysis provides a rationale for the treatment of uncertainties, founded on the principles of probability theory and statistics, and is concerned with a quantifiable measure of the confidence or the reliability associated with any design process. In this thesis, a stochastic approach is employed in the design of flexible pavement structures, to facilitate the development of safe and reliable pavement structures. The important aspects that have been explored in sufficient detail include the system reliability and global sensitivity analysis, and the spatial and temporal uncertainties that pervade the life of pavements. Chapter 1 of the thesis provides an introduction to the stochastic modelling of flexible pavements and its significance in the present day. Highlighting the need for this study, this chapter also enumerates its objectives and presents an overview of the organization of the thesis. Chapter 2 provides a review of the existing literature of the design of flexible pavements and the approaches adopted to deal with the various sources of uncertainties in a probabilistic setting. The estimation of the uncertainties in fundamental pavement design inputs and their integration into the general performance prediction procedures has become a required component of the modern Mechanistic-Empirical pavement design methodology, which has been described in detail. This chapter also provides the scope of the thesis by identifying the areas of stochastic analysis that have received little attention in the flexible pavement design, which include the effect of spatial variability on the pavement structural responses and the techniques of global sensitivity analysis. Chapter 3 provides a detailed overview of the various methodologies adopted in this thesis to carry out the stochastic modelling of flexible pavements. The fundamental technique adopted for the analysis of reliability is the Monte Carlo Simulation (MCS), which relies upon a numerical/analytical model of the physical system, i.e. the pavement model and a probabilistic description of the design parameters represented by random variables or random fields. The high computational expense associated with the MCS, particularly in the case of random fields, is tackled by the use of meta-models based on the stochastic response surface methodology. The chapter outlines the steps followed to develop the meta-models in the form of Polynomial Chaos Equations (PCEs) and its extension to the Sparse PCE that can conveniently represent the spatial variability of the pavement fields. Chapter 4 deals with the probabilistic modelling of flexible pavements, where the design parameter and model uncertainties are quantified based on the available literature studies. The global sensitivity analysis, which aims to study the impact of the input uncertainty on the variation of a model output (critical pavement responses) through uncertainty propagation, is achieved by the construction of the Polynomial Chaos Equations (PCEs). To implement the global sensitivity analysis in a system reliability framework, a generalized approach based on Bayes’ theorem and the concept of entropy as a sensitivity measure, has been proposed in this chapter. Chapter 5 deals with the characterization of the spatial variability inherent in the pavement layer by employing random fields and analyzing the effect on the pavement responses. The discretization of the random field into a vector of random variables is achieved through the simple Midpoint Discretization and the efficient Expansion Optimal Linear Estimation method. Since the computational effort in stochastic problems is proportional to the number of random variables involved, it is desirable to use a small number of random variables to represent the random field. To achieve this, the principle of transformation of the original random variables into a set of uncorrelated random variables through an eigenvalue orthogonalization procedure is adopted. To further increase the computational efficiency of generating random fields for Monte Carlo Simulation, the variance reduction technique of Latin Hypercube Sampling and the meta-modelling technique using Sparse Polynomial Chaos Equations (SPCEs) are implemented. The primary focus of this chapter is to analyze the influence of the spatial variability of the pavement layer moduli, including its anisotropic characteristics on the pavement structural responses. Chapter 6 focuses on the time-dependent reliability of the pavement structures as they age in service, with due consideration given to degradation of strength with traffic loading. The study is concerned with the fatigue reliability and thereby only the decrease in the asphalt modulus with time is considered as a function of the accumulated damage due to repeated loading, whose uncertainty is determined by the uncertainties of material parameters and the traffic loading. The time-dependent model adopted in this chapter can be quite effortlessly embedded in the Mechanistic-Empirical design framework, and provides a tool to effectively schedule the maintenance of the pavement structure and ensure that the reliability level remains at the desired level for the entire design life of the structure. Chapter 7 summarizes the various studies reported in this thesis and highlights the important conclusions.