Determination of Construction Parameters of Porous Ultra-Thin Overlays Based on Laboratory Compaction Studies

To address the severe distresses of asphalt pavement, a new type of pavement maintenance treatment, porous ultra-thin overlay (PUTO) with small particle size was proposed. The PUTO has a thickness of 1.5–2.5 cm and a large void ratio of 18–25%. As a newly asphalt mixture, the structure characteristics differ from poor traditional pavement. Therefore, it is necessary to investigate the fabrication schemes in laboratory and on-site, respectively. In this study, the optimal fabrication schemes, including compaction temperature and number of blows of PUTO were determined based on Cantabro test and volumetric parameters. Then, the corresponding relationship between laboratory and on-site compaction work was then established based on the energy equivalent principle. On this basis, the numbers of on-site rolling passes and the combination method were calculated. The results show that increased compaction temperature and number of blows reduce the height and enhance the compaction of the Marshall sample. With the same temperature and number of blows, the raveling resistance of coarse gradation, Pavement Asphalt Concrete-1 (PAC-1) is better than that of fine gradation, Pavement Asphalt Concrete-2 (PAC-2), and the increased asphalt viscosity significantly improves the raveling resistance of the asphalt mixture. To ensure the scattering resistance and volumetric characteristic, the initial compaction temperature of the PAC-1 and PAC-2 should not be lower than 150 °C and 165 °C, respectively. Then, the laboratory compaction work and on-site compaction work were calculated and converted based on the principle of energy equivalence. Consequently, the on-site compaction combination of rolling machines for four asphalt mixtures was determined. According to the volumetric parameters, the paving test section proved that the construction temperature and the on-site rolling combination determined by laboratory tests are reasonable, and ultra-thin overlay has good structural stability, drainage, and skid resistance.