A research study was conducted with the goal of determining the expected performance life of thin bonded concrete overlay of asphalt (BCOA) in California. Eleven thin BCOA sections were built and tested with the Heavy Vehicle Simulators (HVS) in Davis, California. The performance of the sections in the HVS testing provided insight into the mechanics of the thin BCOA structures and the effects the different rapid-strength concrete materials, traffic, jointing, and base factors on their performance, including testing in both very wet and very dry conditions. Overall, the performance of the thin BCOA sections in the HVS testing was excellent. The eleven sections resisted the predefined HVS loading without cracking. In five of the sections, that loading was equivalent to 6 million single-axle loads and included load levels more than twice the legal limit in California, channelized traffic at the shoulder edge of the slabs, and a continuous water supply that simulated flooded conditions. The main conclusion from this research study is that a well-designed, well-built thin bonded concrete overlay with half-lane width slabs placed on top of an asphalt base that is in fair to good condition can provide 20 years of good serviceability on most of California’s non-interstate roadways.

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Thin bonded concrete overlay on asphalt (BCOA) pavements rely on concrete-asphalt bonding to resist traffic loading. To investigate variables affecting bonding, experimental data were used from 15 instrumented thin BCOA sections, with 11 tested with heavy vehicle simulators (HVS). Sections included three slab sizes, four rapid-strength concrete mixes, new and old asphalt bases, and three asphalt surface texturing techniques. Analysis of strain data from HVS testing served to determine the concrete-asphalt bonding condition. Laboratory testing and forensic data from the sections were also evaluated. Overall, the performance of concrete-asphalt bonding in the sections with 1.8 × 1.8 m (6 × 6 ft) slabs was excellent. In these sections, concrete-asphalt bonding remained intact throughout the HVS testing despite the unfavorable testing conditions, which included flooding of the section, channelized traffic at the slab edge, and HVS wheel (half axle) loading of up to 100 kN (22.5 kips). The sections with 3.6 × 3.6 m (12 × 12 ft) slabs presented a delamination band between the asphalt and concrete along the perimeter of the slabs. This delamination was a tensile break occurring in the asphalt around 5–10 mm (0.2–0.4 in.) below the concrete-asphalt interphase caused by the large vertical hygrothermal deformations in the slabs. Because of this asphalt failure, the concrete and asphalt worked as two independent layers near the transverse joints. Based on laboratory procedures, it was observed that cement paste penetration into the asphalt layer caused a reinforcing effect in the concrete-asphalt interphase. It was also observed that milling and micromilling did not improve the concrete-asphalt bonding.

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