US Army evaluating composites solution for airfield damage repair
The US Army Engineer Research and Development Center (ERDC) is working on use of an FRP matting system to repair damaged military airfields.
The US Army Engineer Research and Development Center (ERDC) reports that it is developing a composites solution to provide matting for airfield damage repair (ADR). The solution, although being developed in-house, will eventually be put out for bid by multiple US Department of Defense agencies.
The fiber-reinforced polymer (FRP) matting system functions as a modular foreign object debris (FOD) cover for ADR consisting of four panel types:
- Full-size panel (216 by 80 inches)
- Half-size panel (112 by 80 inches)
- Full-size anchor panel (216 by 24 inches)
- Half-size anchor panel (112 by 24 inches)
FRP panels are nominally 0.4-inch thick. FRP panels are joined with bushings to form a cover to be placed over a backfilled crater and anchored to the existing pavement by approved anchoring systems. Full- and half-size panels have two adjacent edges recessed at the panel bottom and the two remaining panel edges recessed at the panel top yielding two “overlap edges” and two “underlap edges.” Lower joining bushings are pre-attached to receiving holes located on the underlap edges of full- and half- size panels. Anchor panels are necessary to facilitate the transition from full- and half-size panel underlap edges to open holed edges for anchoring.
Material Composition: FRP panels are fabricated from thermosetting polyester resin and fiberglass reinforcement using a closed molding process. Panels are further reinforced using high-strength aramid fabric in connecting and anchoring areas. Panels are required to exhibit ultraviolet light resistance and meet minimum exposure requirements to prevent degradation during outdoor use and storage.
A typical FRP assembly/set consists of the following components:
| Component | Quantity |
| Full-size panel | 7 |
| Half-size panel | 6 |
| Full-size anchor panel | 3 |
| Half-size anchor panel | 4 |
| Lower joining bushing | 152 |
| Upper joining bushing | 175 |
| Anchor bushing | 125 |
A typical FRP assembly/set can be configured modularly to cover multiple smaller craters (less than or equal to 15 ft) or one larger crater (up to 28 ft). Multiple assemblies/sets can be combined to cover craters of greater size.
Typical installation sequence:
- Assess damaged pavement area
- Determine dimensions of crater
- Saw cut and remove damaged area
- Compact existing subgrade
- Backfill with crushed stone or debris
- Sweep surrounding area
- Assemble FRP cover of desired size
- Anchor leading and trailing edges of FRP cover to existing pavement
The FRP matting system has been verified to sustain 100+ combined passes of C-17 cargo aircraft and F-15 fighter aircraft traffic with regular light maintenance. Live-flight certification testing occurred during September 2009 (ERDC/GSL TR-11-1).
Questions about this program should be directed to Web Floyd (webster.c.floyd@usace.army.mil).
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