Structural design for reflective crack mitigation in the asphalt pavement with a novel prefabricated concrete base

Reflective cracking originating from structural discontinuities at the joints of prefabricated concrete base layers poses a significant challenge to the durability of asphalt concrete pavements. This study presents a systematic approach to mitigate such cracks by establishing evaluation indicators, determining optimization parameters through single-factor analysis, and selecting optimal surface and interlayer designs using orthogonal testing combined with range and variance analyses. The optimal configuration comprises an 8 mm thick stress-absorbing interlayer with a modulus of 400 MPa, paired with a 95 mm thick lower surface layer with a modulus of 1600 MPa. Field validation demonstrated that this design significantly mitigates reflective cracking, with 92% of cracks spaced more than 40 m apart. This indicates a substantial improvement in pavement service life and structural integrity. These findings provide practical guidelines for designing durable asphalt pavements with prefabricated bases, promoting their wider application in urban infrastructure projects.