1. Air Force Research Laboratory Update
UNCLASSIFIED
Air Force Research Laboratory Update
R. Craig Mellerski, Civ, DAF
Aircraft Operating Surfaces - Pavements
Airbase Technologies Division
Tyndall Air Force Base, Florida
April 2012
Distribution A: Approved for public release; distribution unlimited. PENDING
FAA Airport Pavement Working Group Meeting, 23 July 2009

2. Presentation Outline Who we are Pavement aircraft tie-down research
Airfield rubber removal research
High temperature resistant pavement research
Aircraft arresting system research
Rapid airfield repair research
Airfield damage repair (ADR) modernization program
Distribution A: Approved for public release; distribution unlimited. PENDING

3. Mission Statement AIRBASE TECHNOLOGIES DIVISION
Provide Transformational Science and Engineering Solutions for Agile Airbase Operations
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4. Airbase Technologies Division - Where does the lab fit?
AFRL Overview
Airbase Technologies Division - Where does the lab fit?
HQ USAF
HQ AFMC
AFRL RX
Materials and
Manufacturing
Directorate
RXQ
Airbase
Technologies
Division
Distribution A: Approved for public release; distribution unlimited. PENDING

5. Performance Evaluation
What We Do
AOS
Capabilities
Material Development
Materials
Characterization
NDE
Rapid Prototyping
Performance Evaluation
Distribution A: Approved for public release; distribution unlimited. PENDING

6. Facilities / Equipment
Heavy Weight Deflectometer
C-17 Load Cart (277,000 lbs)
F-15E Load Cart (35,000 lbs)
Coring Machine
Asphalt lab Soils lab Material Testing lab
Distribution A: Approved for public release; distribution unlimited. PENDING

7. Facilities / Equipment
Flight Line
Silver Flag
(6000 ft × 125 ft Pavement)
Main Base
AFRL Bldg. 1117
AFRL 9700 Area
(600 ft × 60 ft PCC)
(600 ft × 60 ft HMA)
(100 ft × 60 ft Covered testing)
Gulf of Mexico
Distribution A: Approved for public release; distribution unlimited. PENDING

8. Rigid and Flexible Pavement Aircraft Tie-downs
Objectives
Test traditional shepherds hook PCC and AC tie-downs to determine pull-out capacity
Test contingency (Hat-type and Neenah) tie- downs to determine pull-out capacity
Develop and install simplified AC tie-downs and test to determine pull-out capacity
AFCESA categorizes aircraft tie-downs according to vertical pull-out capacity:
Lightweight capacity—17 kip pull-out resistance
Heavyweight capacity—37.7 kip pull-out resistance
Data Cable
Load Cell
Lifting Hoist
Tie-down
AFRL Anchor-Pulling Apparatus
Technical Approach
Research and test existing traditional aircraft tie-downs
Install and test contingency PCC tie-downs on AOS test-pad
Install and test contingency AC tie-downs in three different subgrades
Identify installation and performance issues
Implementation/Path Forward
Providing Installation kits to FOB locations
Developing protocol and equipment for field certification of existing anchors
Developing common design for both rigid and flexible pavements
Distribution A: Approved for public release; distribution unlimited. PENDING

9. Ultra High Pressure Rubber Removal
Objective
Compare UHPRR Systems
Test and Evaluate TrackJet®
Performance
Deployability
Environmental impact
Ease of operation
Technical Approach
Procure equipment using FCT Program
Train personnel
Conduct rubber removal operations
C-130 deployable
Comparison with domestically manufactured systems
Implementation/Path Forward
Developed evaluation plan
Test locations at Randolph AFB, Tinker AFB, and Camp Shelby
Comparison with detergent rubber removal systems
Draft technical report
Distribution A: Approved for public release; distribution unlimited. PENDING

10. Detergent based Rubber Removal
Objective
Evaluate
Detergent rubber removal system under expeditionary conditions
Dissolve and remove rubber from pavement surface and restore micro/macro textures
Technical Approach
Pre-deployment preparation
C-130 deployable
Conduct rubber removal operations
Demobilize to home base
Status
Performance assessment
Air transportability – successful
Rubber removal – successful
Cost effectiveness – successful
Comparison with ultra high pressure rubber removal systems
Draft technical report
Distribution A: Approved for public release; distribution unlimited. PENDING

11. Implementation/Path Forward
Geopolymer Research
Objective
Develop concrete of high thermal resistance for potential use in JSF launch pads
Optimize mechanics
Increase durability using various fiber materials within matrix
Move towards ambient cure
Technical Approach
Optimize alkali-pozzolanic binder
Investigate micro-chemistry
Vary aggregate and fiber types
Employ different curing methods
Thermal/mechanical load testing
Final report / ETL
Implementation/Path Forward
Investigated effect of constituents on thermal resistance
Investigating effect of fly ash variability on product
Perform rheometry and calorimetry to investigate component contribution to ease of construction
Distribution A: Approved for public release; distribution unlimited. PENDING

12. High Temperature Resistant Flexible Pavement
Objective
Develop flexible binder based (asphalt) high thermal resistance pavements
Optimize mechanics
Develop solutions to transfer loads as a layered structure
Technical Approach
Literature review
Investigate novel materials and modifications to existing materials
Vary coarse and fine aggregates
Thermal/mechanical load testing
Final report / ETL
Implementation/Path Forward
Investigated effect of constituents on thermal resistance
Investigating effect variability of different products
Down select potential solutions
Distribution A: Approved for public release; distribution unlimited. PENDING

13. Aircraft Arresting System (AAS) Retrofits
Objective
Update pavement smoothness criteria for expeditionary AAS
Review existing smoothness/imperfection criteria
Develop new criteria to safeguard against tailhook skip
Technical Approach
Review existing pavement roughness and repair criteria
Model performance of tailhook skip
Evaluate roughness measurement devices
Evaluate device/participate in tests
Develop TTPs
Implementation/Path Forward
Investigate different roughness measuring devices
Field validate models
Down select potential solutions
Distribution A: Approved for public release; distribution unlimited. PENDING

14. Precast Concrete Panels for ADR
Objective
Research current precast concrete panel technology
Install precast concrete panels using different bedding materials
Traffic precast panels and evaluate:
Installation method
Bedding material
Load transfer
Precast Concrete Panel Installation
Technical Approach
Install precast concrete panels on AOS test-pad, utilizing the following bedding materials:
Uretek foam, direct-injection
Uretek foam, deep-injection
Flowable fill
Traffic precast panels 1500 passes with F- 15E load cart
Use heavy-weight deflectometer (HWD) to collect load transfer data before, during, and after trafficking operations
Implementation/Path Forward
Determine the most efficient distressed slab removal and precast concrete panel installation method
Investigating multi-panel emplacements for contingency locations
Developing a repair kit
Distribution A: Approved for public release; distribution unlimited. PENDING

15. Pelletized Asphalt / CRATR JCTD
Objective
Evaluate
Pelletized asphalt technology for ADR
Deployable HMA plant to produce airfield quality HMA
Develop appropriate TTPs 1” 2”
Technical Approach
Laboratory and field studies
Develop/evaluate TTPs
Limited operational utility assessments I and II (LOUA I & II)
Operational utility assessment
Implementation/Path Forward
Performance verified using live aircraft tests
Equipment procurement in process for ADR Modernization Program
Repair kits being revised to include updated equipment and materials
Develop pelletized asphalt technology for expeditionary and sustainment ADR missions while enhancing performance, transportability, ease of use and shelf life.
Deployable Hot Mix Asphalt Plant combines pelletized asphalt with locally procured coarse aggregate to produce a quality mix.
Distribution A: Approved for public release; distribution unlimited. PENDING

16. Implementation/Path Forward
HMA Transport for ADR
Objective
Determine if bottom dump trailer could be used instead of four dump truck loads of HMA
Capable of storing, transporting and placing 18 to 24 tons of asphalt
Capable of being used in freezing temperatures
Technical Approach
Availability and cost of existing material transport vehicles
Evaluate the need for modifications
Investigate vehicle insulation
Conduct thermodynamic analysis (temperature loss)
Implementation/Path Forward
Determine the most efficient method to insulate to allow for longer storage of material
Investigating load and handling of equipment for contingency locations
Develop ETL
Distribution A: Approved for public release; distribution unlimited. PENDING

17. Spall Materials Research
Objective
Subject numerous spall repair materials to lab and field tests
Use test results to determine optimal material for permanent rapid-setting spall repairs of airfield runways
Technical Approach
Select materials for evaluation
Mechanical / thermal testing
Down-select four final materials
Sensitivity tests on final four
Classify each by performance
Final report / ETL
Implementation/Path Forward
Posted material performance test data on central DOD website
Fostered competition among repair material vendors
Distribution A: Approved for public release; distribution unlimited. PENDING

18. Spall Methods and Equipment Research
Objective
Field test various equipment types and excavation methods
Evaluate surrounding slab and underlying strata for damage
Develop excavation and repair method allowing material placement within 15 minutes or less
Technical Approach
Field excavation trials:
Jackhammer, gang saw, hydraulic ram, cold planer
Excavation time vs. final repair quality and bond strength
Load cart testing and analysis
Final report / ETL
Implementation/Path Forward
Recommended new equipment and procedures to decrease repair times and enhance performance
Recognized by TRB’s K.B. Woods Award
Distribution A: Approved for public release; distribution unlimited. PENDING

19. Asphalt Sustainment Kit Evaluation
Objective
Assemble equipment and materials to conduct airfield damage repairs in sustainability environment
Evaluate the vehicles
Minimize redundant equipment
Determine equipment effectiveness
Simplicity of equipment set
Technical Approach
Field testing of materials
Lab testing of materials
Full scale field tests
Identify issues
Report
Implementation/Path Forward
Verification with simulated aircraft loads completed
Supplement repair kits in ADR modernization program
Materials and equipment enhance to the ADR repair kits
Distribution A: Approved for public release; distribution unlimited. PENDING

20. USAF Areas of Interest
Equipment to quickly remove pavement in small areas
Materials that set quickly, cheap, and long shelf life
Lightweight matting for military aircraft loads
Quick assessments of damaged airfields
‘Green’ technologies
Sustainment
Frangible structures
Distribution A: Approved for public release; distribution unlimited. PENDING

21. Questions
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