Failure Investigation of a Foamed-Asphalt Highway Project

This paper documents an investigation into the cause of structural distress (alligator cracking and deep rutting) found in a foamed-asphalt warranty project in Texas. This is a unique forensic study involving a warranty specification, where the contractor may or may not be liable for the cost of repairs, depending on the outcome of the study. Extensive field tests, including FWD, seismic, GPR, and DCP, were conducted. Laboratory tests were also done to determine gradation, moisture content, capillary action, and indirect tensile strength. Four trenches were opened to test each layer directly and to obtain samples for laboratory testing. Two of the trenches were located in distressed/failed areas, while two others were in intact areas. Based on this study, the forensic team concluded that the rutting and alligator cracking are associated with failure of the foamed asphalt base. Since the subgrade strength in the failed areas was similar to the intact areas, the subgrade strength could not have been the sole cause of the failure. The foamed asphalt base was found to be susceptible to moisture and exhibited a severe loss of strength when subjected to moisture. Thus, it is imperative to verify the moisture susceptibility during the design phase. Based on the findings of this study, the contractor did repair the failed section at his own expense.