National Airport Pavement Test Facility Construction Cycle 9 - Volume 5—Flexible Pavement Overload Test
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2026-04-01
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Edition:Final Report
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Abstract:The Federal Aviation Administration (FAA) conducted traffic tests of full-scale flexible airport pavements at the National Airport Pavement Test Facility (NAPTF) as part of Construction Cycle 9 (CC9). Within CC9, the Flexible Pavement Overload Test was designed to develop International Civil Aviation Organization (ICAO) criteria for allowable overload operations. ICAO Annex 14 currently suggests that airports should limit overloads to aircraft having an Aircraft Classification Rating (ACR) not exceeding 10% above the Pavement Classification Rating (PCR). In CC9, the overload test consisted of two test items with the same crosssection but different load histories. One overload test item was subjected to overload traffic up to 75% above PCR, while a second test item received the same regular traffic but did not receive overloads. The overload test was concluded after 56,100 passes of the test vehicle simulating slow-roll taxi operations, in addition to three overload series. Pavement performance was monitored by regular visual distress surveys, nondestructive testing (NDT), and in-pavement sensors. Test results showed that (a) neither the control test item nor the test item with 75% above PCR overloads experienced full structural failure after more than 56,000 passes; (b) both test items experienced significant rutting and extensive surface cracking constituting a functional failure; and (c) measured vertical strains at the top of the clay subgrade differed significantly from the design strains, and continued to increase with accumulated traffic. In part because of the unpredictability of in situ strain and its dependence on non-load factors, the authors propose an alternative criterion for allowable overloads based on the subgrade shear stress ratio (SSR).
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