The recent changes in the Texas Department of Transportation (TxDOT) hot mix asphalt (HMA) mix design procedures to ensure that the mixture types routinely used on Texas highways are not prone to rutting raised concerns that these mixture types are now more susceptible to fatigue cracking. The primary goal of this study was to evaluate fatigue cracking test methods and recommend that which is both simple and robust, especially in qualifying commonly used Texas mixture types. One way to minimize fatigue cracking is through material screening and selection of appropriate mix designs that are representative of fatigue-resistant HMA mixes. However, there are not many standardized laboratory fracture resistance tests that have been universally adopted for routine mix design and/or screening purposes for HMA fatigue resistance. In this study, four different fracture test methods: the Overlay Tester (OT), Direct Tension (DT), Indirect Tension (IDT), and Semicircular Bending (SCB) tests were comparatively evaluated for their potential application as surrogate tests for routine fracture resistance evaluation and screening of HMA mixes in the laboratory. The evaluation criteria included: rationality of the test concept and correlation to field performance, repeatability and variability, simplicity and practicality of the sample fabrication process, and simplicity of data analysis. Results and key findings based on the laboratory fatigue resistance characterization of various commonly used Texas coarse- and fine-graded HMA mixes (Type B, C, and D) are presented in this paper. Overall, preliminary findings indicated that no monotonically-loaded test would be appropriate as a surrogate fatigue resistance test; however, the SCB test showed potential as a repeated-loading test. Suggested SCB test improvements include developing the repeated SCB test protocol, determining the appropriate failure criterion, and correlating laboratory performance to field performance.

Several different types of modifiers are increasingly being used to improve the performance of asphalt binders or to achieve desired mixture production characteristics (e.g., Warm Mix Asphalt). However, current Superpave performance specifications do not accurately reflect the performance characteristics of these modified binders. The main objective of this study was to evaluate the inherent fatigue cracking resistance of asphalt binders in the form of a matrix with rigid particle inclusions. The underlying rationale for this approach was to subject the binders to a state of stress that is similar to the one in a full asphalt mixture. This was achieved by fabricating and testing composite specimens of the asphalt binders and glass beads with a specified gradation. Four asphalt binders with similar true temperature grades but different modifiers were used in this study. The viscoelastic and fatigue cracking characteristics of the binders were measured using the glass bead-binder composite specimens in a dynamic shear rheometer at an intermediate temperature. The results demonstrate that the four asphalt binders modified using different methods had different damage characteristics despite the fact that these four binders were rated to have a similar performance grade based on the Superpave specifications. Fatigue cracking characteristics of the glass bead-binder test specimens used in this study were qualitatively very similar to the fatigue cracking characteristics of full asphalt mixtures using the same binders. The rank order of fatigue cracking resistance for the four glass bead-binder mixtures compared reasonably well to the rank order of fatigue cracking resistance for the full asphalt mixtures that incorporated these asphalt binders.

The development process included a number of phases, which are described in the report. Included in this report are the following: 1) a state-of-knowledge review for fatigue response of asphalt aggregate mixes, 2) a description of a pilot test program and its results, 3) a description of an expanded test program using the equipment and methodology selected in the pilot test program, and 4) a description of a mix analysis and design system, which can be used to mitigate fatigue cracking.

Fatigue cracking is one of the fundamental distresses that occur in the life of a Hot Mix Asphalt Concrete (HMAC) pavement. This load induced distress leads to structural collapse of the entire pavement ultimately and can only be remedied by rehabilitation. There is the need, therefore, for a total understanding of the phenomenon to be able to counter its occurrence. The fatigue resistance of hot mix asphalt concrete (HMAC) has been estimated using approaches ranging from empirical methods to mechanistic-empirical methods to purely mechanistic methods. A continuum mechanics based approach called the Calibrated Mechanistic with Surface Energy (CMSE) measurements was developed at Texas A & M University and recommended after comparison with other approaches in predicting fatigue lives of two Texas HMAC mixtures. The CMSE approach which includes fundamental material properties such as fracture, aging, healing, and anisotropy has been shown to effectively model the parameters that affect the performance of HMAC pavements exposed to repetitive traffic loads. Polymer modified asphalt (PMA) improves pavement performance by providing additional resistance to the primary distresses in flexible pavements, including permanent deformation or rutting, thermal cracking, and fatigue cracking. In this research, the CMSE approach was utilized to estimate the fatigue resistance of HMAC fabricated with asphalts modified with Styrene-butadiene-Styrene (SBS) co-block polymer. These HMAC mixtures were fabricated from materials used on three different road sections in Texas and one test pavement in Minnesota. The CMSE approach was validated as an effective approach for estimating the fatigue resistance of HMAC mixtures with PMA. The effect of oxidative aging on the fatigue resistance of the HMAC mixtures was also verified. Oxidative aging of the mixtures resulted in a corresponding decrease in mixture fatigue resistance. In addition, for two HMAC mixtures with the same binder content and aggregate gradation, the mixture with the softer of the two Performance Grade (PG) binders exhibited greater fatigue resistance. The use of the Utility Theory revealed the possible effects of aggregate geometric properties on the HMAC mixture properties and consequently on their fatigue resistance.

At head of title: National Cooperative Highway Research Program.