Targeted Overlay Pavement Solutions (TOPS) build on conventional overlay methods and include new overlay materials and techniques. TOPS, a Federal Highway Administration (FHWA) Every Day Counts Round 6 (EDC-6) innovation that Pennsylvania championed, offers 13 options to help ensure safe, longer-lasting roadways.
Of the 13 options available, PennDOT has piloted Highly Modified Asphalt and Bonded Concrete on Asphalt and has already adopted the use of Unbonded Concrete Overlay on Concrete, High-Performance Thin Overlay, Stone Matrix Asphalt, Asphalt Rubber GapGraded and Ultra-Thin Bonded Wearing Course.
In August 2023, PennDOT received a $700,000 grant from FHWA's Accelerated Innovation Deployment (AID) Demonstration program to improve the long-term resiliency of pavement on roads throughout the state. The funding will be used to deploy solutions like Stone Matrix Asphalt and Highly Modified Asphalt in several PennDOT districts. These pavement solutions are more durable and cost-effective than traditional overlay methods and extend the lifespan of a roadway in a relatively short timeframe. This reduces the need for long-term lane closures and continuous roadway reconstruction projects. In addtion the solutions increase skid resistance.
TOPS is already being used on many projects throughout Pennsylvania. More recently, PennDOT piloted Bonded Concrete on Asphalt Overlay with Fibers on State Route 28 in District 10, which is located in the northwestern region of the state. The project used a special provision, which included the newly drafted language for using fibers.
In District 6, in the southeastern region of the state, Highly Modified Asphalt was used during the paving of a high-traffic area on Interstate 95. In District 1, in the northwestern corner of the state, Highly Modified Asphalt was used as part of a larger pilot project on approximately one mile of Interstate 79.
Asphalt Rubber Gap-Graded was tested along sections of four different roadways: State Route (SR) 15 in Adams County, District 8, I-78 in Berks County, District 5, I-376 in Lawrence County, District 11, and SR 15 in Snyder County, District 3.