03 Port and Harbour HaTelit May 2021

Asphalt Reinforcement with Polyester Grids:
Proof of Effectiveness
05.05.2021 Unternehmenspräsentation
Asphalt Reinforcement 1
Agenda
Reflective cracking
Retardation of reflective cracking due to asphalt reinforcement
Key requirements for asphalt reinforcement grids to be effective
Proof of effectiveness by research
Selected case studies
Conclusions
Reflective cracking
from existing base Wearing course

Binder course / concrete
on carriageway widening schemes Bearing course
Subgrade
at joints between paver passes
above the location of road excavation
above expansion joints in concrete
pavements
from aging of bitumen (e.g. oxidation)
Reasons for reflective cracking
Dynamic load
Shear action + Bending action Shear action -
Reflective cracking
Crack growth into the new asphalt layer
Due to high tensile stresses at crack tip
Source 1: Montestruque G. E., 2002, Contribuição para a Ela-boração de Método de Projeto de Restauração de
Pavimentos Asfálticos Utilizando Geossintéticos em Sistemas Anti-Reflexão de Trincas (Contribution to the
preparation of a method of a project for rehabilitation of asphaltic pavements using geosynthetics on anti-reflective
crack systems). Doctoral Thesis, Technological Institute of Aeronautics, São José dos Campos, Brazil.
Unternehmenspräsentation
Asphalt Reinforcement
Operating mode of reinforcement grids
Absorption and distribution of high tensile stresses
Significantly reduced growth of reflective cracks
Source 1: Montestruque G. E., 2002, Contribuição para a Ela-boração de Método de Projeto de Restauração de
Pavimentos Asfálticos Utilizando Geossintéticos em Sistemas Anti-Reflexão de Trincas (Contribution to the
preparation of a method of a project for rehabilitation of asphaltic pavements using geosynthetics on anti-reflective
crack systems). Doctoral Thesis, Technological Institute of Aeronautics, São José dos Campos, Brazil.
Retardation of reflective cracking
Asphalt interlayers
Nonwovens
sealing function
Reinforcement grids
w/o installation aid
reinforcing function
Composites (nonwoven and grid)

sealing and strain reducing
function
evtl. reinforcing function
Advantages of asphalt reinforcement
Up to 4 times better retardation of
reflective cracks
Extension of rehabilitation intervals
Extension of service life
Reduction of maintenance costs
Very economic solution for
rehabilitation of traffic areas
Demands on asphalt reinforcements
Straightforward and reliable installation
Resistance against installation damage
Enables a good bond strength
Key requirements for asphalt reinforcement grids
Straightforward and reliable installation
Resistance of the grid against installation damage during paving
Raw material: e.g. “flexible robust Polyester (PET) polymers” vs. “brittle glass-fibres”,
when engineering for continuous reinforcement throughout the grid
Enables and promotes a good bond strength
Durability
e.g. raw material's resistance to heat and chemical degradation
Compatibility
e.g. thermal expansion coefficient of the reinforcing grid and asphalt must be
compatible to allow optimum load transfer
Allows successful milling and recycling for future maintenance
Demand: Straightforward and reliable installation
A good reinforcement is flexible and adaptable.
An installation aid (nonwoven backing) protects against displacement.
A bituminous coating ensures excellent adhesion to base.
The installation aid should not require any extra work steps.
Broad and long rolls reduce the number of overlaps and allow higher
installation rates
Demand: Resistance
High resistance
when driven over by asphalt trucks or
tracked pavers
during compaction of asphalt
When laying on milled surfaces
In alkaline environments (when installed on

concrete surfaces)
Demand: Good bond strength
A good asphalt reinforcement supports the bond strenght via
Interlock Mesh size
Adhesion Bituminous coating
Friction Mesh size and coating
®
HaTelit C
Optimum retardation of reflective Property
®
HaTelit C
cracking (40-year track record) Elongation at break < 12%
Very high resistance to installation Tensile strength 50 kN/m
damage Bitumen content of coating > 60%
High resistance to long-term dynamic Tensile strength after installation damage

test (DIN EN ISO 10722)) > 90%
traffic loads Ratio of strength of damaged specimen to

nominal strength of reinforcement grid > 80%
No loss of strength due to moisture
Raw material Polyester
Cuttable Yes
Roll length 150 m
Roll width Up to 5 m
Mesh size 4 cm
®
SamiGrid
Composite comprising PVA Property SamiGrid
®
reinforcement grid and 130 g/m² Elongation at break < 6%

nonwoven Tensile strength 50 kN/m
Ideal for rehabilitation of concrete Bitumen content of coating > 60%
pavements (alkali-resistant) Tensile strength after installation damage

> 90%
test (DIN EN ISO 10722))
Stress-relieving and reinforcing function Ratio of strength of damaged specimen to
> 80%
nominal strength of reinforcement grid
Very high resistance to installation Raw material PVA
damage Weight nonwoven 130 g/m²
Cuttable Yes
Roll length 100 m
Roll width Up to 5 m
Mesh size 4 cm
Proof of effectiveness by research
Doctoral Thesis, Technological Institute of Aeronautics, São José dos

Campos, Brazil, 2002.
Dynamic Fatigue Tests to Determine the Effects of HaTelit® in Anti

Reflective Cracking Applications in Asphalt Overlays
Crack Retardation; Research (2000):
Material: Flexible, bitumen-coated,

high-tenacity PET specialised
asphalt reinforcement grid
Precrack: 3 mm, 6 mm, 9 mm
Reinforcement-position: Directly above the crack tip
Load position: Bending and shear mode
Contact pressure: 560 kN/m² (max. value)
(1) Overlay
(2) Blocks with opening
(3) Elastic base (rubber)
Typical crack without reinforcement
Typical crack
(Without reinforcement)
N=79,884
Typical crack with reinforcement
Typical crack
(with reinforcement)
N=503,832
Selected Case Studies
Salgado Filho Airport, Porto Alegre, Brazil
Source: Monser C.A., Montestruque G.E., Silva A.E.F., (2010), Evaluation of an airport pavement after almost 8 years of
overlay rehabilitation with a Polyester geogrid asphalt reinforcement, 9th International Conference on Geosynthetics, Brazil
Background
In January 2002, Taxiway Golf was rehabilitated following over 40

years in service
Typical traffic loads
e.g. Boeing 777 with a gross weight of 250 t
The pre-existing Taxiway Golf was made of concrete slabs, in a
condition exposed to cracks as well as voids below the concrete
slabs.
Pre-existing Taxiway Golf in January 2002
250mm
Bearing course
Concrete slabs
5m x 3.5 m
Overlay rehabilitation proposed

Concerns around reflective cracking, especially from the joints, were
considered as part of the design
Rehabilitation in January 2002
1. Filling of expansion joints and cavities

2. Construction of an asphalt levelling course (20 mm)
3. Installation of asphalt reinforcement
4. Construction of a 50 mm (compacted) asphalt overlay
50mm AC overlay
HaTelit® C 40/17
20mm corrector layer PET Grid
Concrete slabs
Bearing course
Rehabilitation in January 2002
Works competed during the same shift

Due to a very tight timeframe, asphalt reinforcement was installed
only in critical area in the middle of the taxiway
The border area was left unreinforced where the aircraft normally do
not taxi
Condition after 8 years
unreinforced reinforced
Condition after 8 years
unreinforced
reinforced
unreinforced
Highway MG-424, Minas Gerais, Brazil
The MG-424 is a public dual

carriageway with heavy traffic
loads, in the Brazil. The existing
pavement consists of concrete
slabs which received an asphalt
resurfacing.
In 2012, the pavement was
severely damaged, and the joints
and cracks of the rigid pavement
had propagated through the asphalt
overlay, resulting from the thermal
stress arising from temperature
changes and different coefficients
of thermal expansion from concrete
and asphalt.
The rehabilitation design involved first milling off

the existing asphalt layer and placing a 40 mm
asphalt leveling course. Installation of HaTelit
asphalt reinforcement. Then, a 50 mm asphalt
surface course.
At the beginning of 2013 the highway MG-424
was resurfaced. However, after milling off the
existing asphalt, the 40 mm placed asphalt
levelling course was not immediately covered.
Almost two months after its installation, some
thermal cracks could be observed in the surface.
Early reflective cracking (March 2013)
The expansion joints from the concrete slab had
reflected through this new asphalt overlay.
In April 2013, HaTelit asphalt reinforcement grid was installed on the levelling layer, and was
covered with the 50 mm asphalt surface course.
The reinforced area in the highway still does not show any cracking. The use of a polyester
grid delayed the propagation of reflective cracks developing from the expansion joints of the
concrete slabs.
The case study showed that the

use of an asphalt reinforcement
in concrete pavement
rehabilitation can be
advantageous. The use of HaTelit
grid has to date prevented the
propagation of expansion joints
and cracks through the new
asphalt overlay in a high-traffic
highway.
Ochtrup-Rosenstrasse Road Rehabilitation, 1996
Very high traffic volume incl. Trucks (through road to The Netherlands)
Road condition:
Very bad
Brittle
Cracks in all directions
Planing: Milling of existing wearing course (5 cm) and replacement by a new bearing course
Installation of a completely new pavement incl. Bearing and binder course

Difficult to perform (time factor)
Very expensive
Installation of a reinforcement to extend the time till next rehabilitation
Installation: 13.05.1996
First inspection: 15.05.2001
Last inspection: April 2010
2001
1996
Despite of a increasingly high traffic volume…
2001
2010
2005
Result
Some isolated cracks were found in the

border area of the street.
Reason
10 - 20 cm
 The whole reinforced area was free of cracks.
Manila International Container Terminal, 1995
Manila International Container Terminal, 1995
Conclusion
A suitable asphalt reinforcement grid made from high modulus polyester (PET)
with a bituminous coating is a highly effective solution against reflective
cracking in asphalt overlays.
Polyester’s high resistance against installation damage is a key factor for
successful stress absorption/distribution and effective crack retardation
Service life of the rehabilitated pavement can be extended considerably by
using a high modulus polyester asphalt reinforcing grid.
As a result, significant advantages in reducing maintenance costs as well as
construction disruption to airfield operations can be achieved.
Thank you very much for your attention!

03 Port and Harbour HaTelit May 2021

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Asphalt Reinforcement with Polyester Grids:

from existing base Wearing course

Shear action + Bending action Shear action -

Crack growth into the new asphalt layer

Due to high tensile stresses at crack tip

Absorption and distribution of high tensile stresses

Significantly reduced growth of reflective cracks

Composites (nonwoven and grid)

Straightforward and reliable installation

Resistance against installation damage

Enables a good bond strength

A good reinforcement is flexible and adaptable.

An installation aid (nonwoven backing) protects against displacement.

A bituminous coating ensures excellent adhesion to base.

When laying on milled surfaces

In alkaline environments (when installed on

A good asphalt reinforcement supports the bond strenght via

Interlock Mesh size

Adhesion Bituminous coating

Friction Mesh size and coating

High resistance to long-term dynamic Tensile strength after installation damage

traffic loads Ratio of strength of damaged specimen to

Roll length 150 m

reinforcement grid and 130 g/m² Elongation at break < 6%

Ideal for rehabilitation of concrete Bitumen content of coating > 60%

pavements (alkali-resistant) Tensile strength after installation damage

Doctoral Thesis, Technological Institute of Aeronautics, São José dos

Dynamic Fatigue Tests to Determine the Effects of HaTelit® in Anti

Material: Flexible, bitumen-coated,

In January 2002, Taxiway Golf was rehabilitated following over 40

Overlay rehabilitation proposed

1. Filling of expansion joints and cavities

Works competed during the same shift

The MG-424 is a public dual

The rehabilitation design involved first milling off

The case study showed that the

Installation of a completely new pavement incl. Bearing and binder course

Some isolated cracks were found in the

 The whole reinforced area was free of cracks.

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