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<p>Concrete overlays are widely adopted as a rehabilitation strategy to restore structural capacity and extend the service life of deteriorated flexible pavements. The structural performance of such composite systems is governed by the mechanical interaction between overlay and substrate, interface bonding condition, and thermo-mechanical stresses developed under traffic loading. This study presents a mechanistic structural response based methodology for determining the required thickness of cement concrete overlay placed over an in-service bituminous pavement. The existing pavement structure is transformed into an equivalent elastic foundation system using back-calculated effective modulus of subgrade reaction derived from ASTM-based correlations. The overlay thickness is determined by equating combined wheel load induced bending stress and temperature-induced warping stress with the flexural capacity of concrete. Both bonded and unbonded interface conditions are analytically modelled to evaluate composite action and stress transfer mechanisms. Results indicate that interface bonding significantly enhances load-sharing behaviour and reduces required overlay thickness. Unbonded overlays require substantially greater thickness due to reduced composite stiffness and increased tensile stress demand. Overlay thickness increases with slab panel size and temperature differential, while improved subgrade strength reduces thickness requirement. The proposed method shows good agreement with IITPAVE simulations and established recommendations of NCPTC and ACI guidelines, demonstrating its reliability as a mechanistically consistent alternative approach for concrete overlay design.</p>

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Thermo-Mechanical Response of Concrete Overlay-Bituminous Substrate Composite Systems under Variable Interface Bonding

  • 期刊论文

  • 发表日期：

    2026年5月19日

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  • Arghya Banerjee,
  • Partha Pratim Biswas,
  • Manoj Kumar Sahis,
  • Sourav Paul,
  • Soumyadeep Paty

摘要

Concrete overlays are widely adopted as a rehabilitation strategy to restore structural capacity and extend the service life of deteriorated flexible pavements. The structural performance of such composite systems is governed by the mechanical interaction between overlay and substrate, interface bonding condition, and thermo-mechanical stresses developed under traffic loading. This study presents a mechanistic structural response based methodology for determining the required thickness of cement concrete overlay placed over an in-service bituminous pavement. The existing pavement structure is transformed into an equivalent elastic foundation system using back-calculated effective modulus of subgrade reaction derived from ASTM-based correlations. The overlay thickness is determined by equating combined wheel load induced bending stress and temperature-induced warping stress with the flexural capacity of concrete. Both bonded and unbonded interface conditions are analytically modelled to evaluate composite action and stress transfer mechanisms. Results indicate that interface bonding significantly enhances load-sharing behaviour and reduces required overlay thickness. Unbonded overlays require substantially greater thickness due to reduced composite stiffness and increased tensile stress demand. Overlay thickness increases with slab panel size and temperature differential, while improved subgrade strength reduces thickness requirement. The proposed method shows good agreement with IITPAVE simulations and established recommendations of NCPTC and ACI guidelines, demonstrating its reliability as a mechanistically consistent alternative approach for concrete overlay design.