Development of Foam Backfill Repair Techniques for Airfield Pavement Repairs

Abstract

Recent military operations have highlighted the need for new expedient pavement repair capabilities to improve current guidance on airfield damage repair. Damaged or distressed military airfield pavements must be repaired with expedient methods and durable materials to minimize the time the pavement is removed from service and to reduce or eliminate additional closure times for subsequent repairs. Extensive research was conducted to develop several airfield pavement repair techniques that could be applied across the full spectrum of military airfield repair operations. This paper focuses on the research conducted to develop a new foam backfill technology for airfield pavement repairs. Results of initial laboratory and field tests showed that rigid, poured polyurethane foam is the most applicable backfill solution for deployed locations because of its ability to expand to several times its shipped liquid volume when mixed, reducing the logistical burden of transporting aggregate backfill materials. This paper describes laboratory and field experiments that used foam backfill and prototype equipment to develop a pavement repair technique that supports threshold and objective aircraft pass levels defined for expedient airfield repairs. The research included laboratory testing, full-scale field testing, and simulated and actual aircraft traffic tests with C-17 and F-15 aircraft. Results of these tests validated and certified the foam backfill repair technique for military aircraft use. However, these experiments also identified material and equipment limitations that will require additional research before the repair technique is adopted by military repair teams. Conclusions and recommendations for future equipment and material improvements are provided.