The progressive degradation of railway ballast over time increases the degree of ballast fouling and poses significant drainability concerns leading to frequent maintenance activities. To avoid such issues, an effective and continuous characterization of the physical properties of the ballast layer is deemed necessary. This paper introduces the combined use of a bender element (BE) piezoelectric field sensor and a PANDA^® dynamic cone penetrometer for periodic evaluations of ballast condition over the traffic use. To simulate various levels of ballast degradation, box tests were conducted using a dolomitic ballast material compacted in a laboratory-sized testbed with fouling indices ranging from zero to 39%. BE sensor pairs were embedded in the ballast layer to calculate the small strain modulus behavior of the ballast assessed through shear wave velocity measurements under different confinement conditions. Strength profiles of the ballast at different fouling levels were also measured using the PANDA^® penetrometer. Experimental findings from both test methods indicate the existence of a dense state of ballast linked to a certain fouling index that maximized stiffness and strength characteristics of the tested ballast in dry condition. Accordingly, the potential use of BE field sensors embedded within in-service ballasted track coupled with periodic penetration testing can be a viable approach to evaluate ballast layer degradation. Various void packing conditions associated with ballast fouling levels can be linked to important ballast layer modulus and strength behavior. Further, such smart sensing of ballasted track behavior can provide long-term performance monitoring solutions for ballast cleaning and maintenance scheduling.

The bender element (BE) field sensor is a newly developed embedded pavement instrumentation that measures shear wave velocity to estimate constructed layer moduli of unbound aggregate bases and subbases. This paper presents findings related to monitoring stiffness characteristics of airport pavement base courses instrumented with BE field sensors and tested under full-scale accelerated pavement testing during Construction Cycle 9 (CC9) of the National Airport Pavement Test Facility (NAPTF) by the U.S. Federal Aviation Administration (FAA). The CC9 aggregate base courses were constructed following FAA’s P-209 specification for a geosynthetic experiment using a biaxial geogrid installed at the bottom of the 8-in. (203-mm) thick base in the north test section, while the control pavement in the south test section was built without a geogrid. Two BE field sensors were installed in the north and south test sections approximately 1 in. (25 mm) above the base–subbase interface. Multiple stages of aircraft gear loads, including static dual-gear, dynamic slow-roll (moving wheel), and dynamic proof-roll, were applied to the test sections. BE field sensor data collected throughout multiple loading stages were used to investigate the stiffness characteristics of the pavement base. These preliminary tests conducted at the NAPTF CC9 experiment revealed the effects of static and dynamic aircraft gear loads on the stiffness of the aggregate base layer and how confinement influenced the moduli of the geogrid-stabilized base. Further, previously observed anti-shakedown effects caused by vehicle load wander could be quantified through changing base course modulus and deformation behavior from the BE field sensor data analysis.

Geogrids are commonly used in paved and unpaved roadways to stabilize base and subbase layers by laterally restraining movements of unbound aggregates under applied wheel loading, often referred to as interlocking. The geogrid-aggregate interlock is a function of the match between the geogrid aperture size and geometry and the grain size and shape characteristics of the stabilized aggregates. Open-graded coarse aggregates (OGA) are commonly used as an alternative to dense-graded materials in permeable base/subbase applications as well as in railway ballast to facilitate drainage. This paper describes an experimental study recently conducted to investigate the repeated load-deformation behavior of a geogrid-stabilized OGA material in large-scale triaxial testing. Two multi-axial geogrids with the same aperture patterns but different aperture sizes were tested. The aperture patterns include different sizes of hexagonal, trapezoidal, and triangular openings. The multi-axial geogrid with the larger apertures better matched the OGA material properties to provide a reduction in permanent deformation in the test specimen. The improved interlocking and the related local stiffness enhancement were successfully quantified using embedded shear wave transducers termed bender elements. To stabilize aggregates with relatively uniform grain sizes, for example, AASHTO No. 57 stone studied here and railroad ballast, the ratio between the aperture size and a representative particle size (i.e., D₉₀) served as a good indicator of the effectiveness of the geogrid. The findings of this experimental study therefore provided valuable information on the governing properties and mechanisms that play a role in geogrid-aggregate interaction with multi-axial geogrids.

This paper integrates and extends an earlier article presented at the 20th International Conference on Soil Mechanics and Geotechnical Engineering. The generation of a stiffened zone in the proximity of a geogrid is one of the primary mechanisms of mechanical stabilization of pavement unbound aggregate layers using geogrids. This paper focuses on the quantification of the stiffened zone through a local stiffness assessment using bender element (BE) sensors. Unbound aggregate base layers were constructed in a large-scale laboratory testbed. Geogrid-stabilized layers had geogrids with different-sized triangular apertures contributing to the geogrid-stiffened zone. Shear wave velocities were measured at three different heights using BE sensors, and the vertical stiffness profiles of the mechanically stabilized aggregate layers were evaluated. In addition, the conversion method between small-strain stiffness and large-strain stiffness was established from the repeated load triaxial tests with BE pairs to transform the vertical stiffness profile into that of the resilient modulus. Furthermore, dynamic cone penetration (DCP) and light-weight deflectometer (LWD) tests were performed at multiple locations into the stabilized and unstabilized unbound aggregates. From the large-scale experimental study, the local stiffness improvement owing to the geogrid enhancement was up to 16.2% in the vicinity of the geogrid location, and the extent of the local stiffened zone evaluated through various test methods was between 15.2 cm (6 in.) and 25.4 cm (10 in.) above the geogrid.

Real-time stiffness monitoring of unbound aggregate layers using embedded field sensors is crucial for advanced airport pavement design and management. This paper describes research findings on monitoring base layer stiffness characteristics for airport pavements using an embedded bender element (BE) field sensor, inductive coil sensors, and pressure cells. A full-scale pavement test section was constructed at the Federal Aviation Administration (FAA)’s National Airport Pavement Test Facility (NAPTF). A BE field sensor, inductive coil sensor pairs, and pressure cells were installed in the unbound aggregate base to evaluate the layer stiffness, applied load stress, and deformation characteristics. A triple dual tandem gear loading module applied 58,000 lb per wheel to the tested section with a wander pattern consisting of 66 passes arranged in nine lateral wander positions. Dynamic responses of coil sensors and pressure cells were collected during the traffic test, whereas BE signals were collected after completing each wander pattern. Laboratory repeated load triaxial tests with BE instrumentation were also conducted to establish a correlation for converting BE field sensor readings to layer modulus properties. The in situ modulus characteristics of the aggregate base layer were evaluated during full-scale testing using two methods: shear wave velocities from a BE field sensor, and strain and stress measurements from coil sensors and pressure cells. The moduli estimated using both approaches fell into typical ranges of crushed aggregate bases and were highly comparable. The moduli from the dynamic sensor measurements clearly showed the effect of vehicle wander on aggregate base layer measured responses.

Geogrid inclusion in low-volume road applications has been shown to improve rutting performance. Although rutting performance and traditional instrumentation response data provide meaningful insights into pavement behavior, they do not provide a direct measurement of material behavior near the geogrid. Recently, the University of Illinois at Urbana-Champaign has developed field-deployable shear-wave transducers, that is, bender elements to measure the localized stiffness enhancement attributed to geogrid inclusion in unbound aggregate layers, which have been verified in laboratory and limited field applications. Bender element sensors were installed in a full-scale accelerated pavement test experiment at the U.S. Army Engineer Research and Development Center that included a recently developed multi-axial hexagonal geogrid. The sensors were installed directly on the geogrid and 10 cm above the geogrid in the unbound aggregate layer to measure the geogrid zone of influence. The test item was trafficked with a dual-wheel truck gear, and bender element measurements were made at select intervals throughout traffic application. To estimate the unbound aggregate moduli, the data were analyzed using two techniques: first arrival time and peak-to-peak arrival time. The bender element sensors were found to be sufficiently robust to survive installation, construction, and trafficking. Calculated modulus values 10 cm above the geogrid were found to be higher than those directly on the geogrid, which was an unexpected finding. However, a forensic investigation revealed moisture and fines migration into the bottom of the unbound aggregate layer, which could have dampened the shear-wave signal, resulting in lower calculated modulus values.