Evaluation of FAA Airport Pavement Design Methods Using Long-Term Pavement Condition Data

This study evaluated the Federal Aviation Administration’s (FAA) pavement design methodology using empirical pavement condition data collected from 179 commercial service airports across the United States. Pavement condition index (PCI) and structural condition index (SCI) values were computed using FAA PAVEAIR software for over 10,000 runway and taxiway sections, including Portland cement concrete (PCC), asphalt concrete, asphalt over asphalt concrete, and asphalt over PCC surfaces. Pavement age was determined based on inspection, construction, and maintenance history. Filtered data were used to assess performance trends by surface type and validate theoretical deterioration models. Results showed that the bilinear SCI model for rigid pavements closely matched observed data, with an inflection point of nearly 24 years. However, measured SCI data before the inflection point indicated some deterioration, challenging the design assumption of no damage before the inflection point. Flexible pavements deteriorated faster than rigid pavements, with a majority of distresses being environment-related including longitudinal and transverse cracking, joint reflection cracking, weathering, and raveling. The average age at rehabilitation was 15–18 years for flexible pavements and 32 years for rigid pavements, with PCI values typically between 61 and 67 at the time of rehabilitation. The findings confirm the general validity of existing design models but also highlight embedded conservatism, particularly in rigid pavement design. The results suggest that the FAA’s initiative to extend airport pavement design life to 40 years must consider environmental-related distresses and include planning for rehabilitations over the service life.