Forensic Evaluation of Premature Failures of Texas Specific Pavement Study–1 Sections

The Specific Pavement Study–1 pavement test section on US281 in south Texas comprise the largest Strategic Highway Research Program experimental site in the United States. The project was opened to traffic in 1997, and performance has been poor. Three of these test sections developed deep rutting within 1 year. Their surfaces were milled to restore ride quality. Three years after construction, 14 of the sections had 10 mm or more rutting. A forensic study was initiated by the Texas Department of Transportation to identify the cause of the problem. Nondestructive testing was conducted with both the falling weight deflector and ground penetrating radar. No structural problems were detected with either device, both indicating that the base and subbase layers were strong. A field investigation was initiated; the original plan was to cut nine trenches, however, after four trenches were cut, the problematic layer was identified and the trenching operation was terminated. Dynamic cone penetrometer, stiffness gauge, seismic pavement analyzer, and nuclear density gauge tests were then conducted on top of the base and subgrade layers. The trench profiles indicated that the rutting was coming primarily from the top 50-mm (2-inch) asphalt-concrete layer. Asphalt cores were taken from both rutted and nonrutted sections and bag samples of the base were tested in laboratory. The binder was recovered, and the asphalt content and penetration, aggregate gradation, and type were determined. The cause of the problem was traced to a change in aggregate screening, and also an excess of asphalt in the top layer.