Critical Stress Conditions for Foam Glass Aggregate Insulation in a Flexible Pavement Layered System

In cold regions, flexible pavements are vulnerable to frost-induced damage, necessitating effective insulation strategies. Foam glass aggregate (FGA) insulation layers, made from recycled glass, offer promising thermal insulation properties but are mechanically fragile and susceptible to permanent deformation under repeated loading. Manufacturers provide technical recommendations, particularly regarding load limits for installation and the dimensions of the thermal protection layer. These are considered insufficient to assist pavement designers in their work. The definition of critical criteria for permissible loads was deemed necessary to design mechanically durable structures using this alternative technology. This study investigates the critical stress conditions that FGA layers can tolerate within flexible pavement systems to ensure long-term structural integrity. Laboratory cyclic triaxial tests and full-scale accelerated pavement testing using a heavy vehicle simulator were conducted to evaluate the resilient modulus and permanent deformation behavior of FGA. The results show that FGA exhibits stress-dependent elastoplastic behavior, with resilient modulus values ranging from 70 to 200 MPa. Most samples exhibited plastic creep or incremental collapse behavior, underscoring the importance of careful stress management. A strain-hardening model was calibrated using both laboratory and full-scale data, incorporating a reliability level of 95%. This study identifies critical deviatoric stress thresholds (15–25 kPa) to maintain stable deformation behavior (Range A) under realistic confining pressures. FGA performs well as a lightweight, insulating, and draining layer, but design criteria remain to be defined for the design of multi-layer road structures adapted to local materials and traffic conditions. Establishing allowable critical stress levels would help designers mechanically validate the geometry, particularly the adequacy of the overlying layers. These findings support the development of mechanistic design criteria for FGA insulation layers, ensuring their durability and optimal performance in cold climate pavements.