1 Oct 2025

US Army Water Reuse: 2023 Survey of Wastewater Reuse at US Army Installations

Abstract: The US Army Corps of Engineers, Engineer Research and Development Center, Construction Engineering Research Laboratory (USACE ERDC-CERL), partnered with the US Army Material Command (HQAMC G4) to collect information on water use and wastewater to understand water re-use at the installation level by distributing a water reuse questionnaire. From May to September 2023, ERDC-CERL compiled the 98 responses received from all Army installations and established the following baseline data for water reuse: the US Army produces 35.9 million gallons per day (MGD) of effluent, 30.4 MGD of which receives a minimum of secondary treatment making it potentially eligible for reuse, however the US Army currently only reuses 4.51 MGD. Current reuse practices save the Army up-wards of $751,849 every month in potable water cost offsets; however, the Army could potentially save approximately $4.3 million every month if they expanded their water reuse to its current full capacity (including re-use of effluent receiving secondary or tertiary treatment). This project will be foundational for continual studies of water reuse in the Army. It will aid in creating installation energy and water plans (IEWPs), in developing a proposed geospatial dashboard tool, and in further water reuse projects with other Department of Defense departments.

25 Sep 2025

Train Loadings on Bridges for US Army Installations: Guidance

Abstract: Railroad bridges on US Army installations must be rated to determine the safe load limits for the trains that utilize them. In addition to the standard Cooper E-80 loading required by the Federal Railroad Administration, specific locomotives and railcars that use the bridges must also be considered in the load ratings. For that purpose, this report documents the authors’ efforts to compile detailed dimensional- and axle-loading data on all Army-owned locomotives and railcars and then to develop a set of Army-specific rail equipment loadings for use in bridge load ratings. This report provides a detailed description of the data compilation and load development process that resulted in the Army-specific rail equipment loadings.

23 Sep 2025

Naval Expeditionary Runway Reconstruction Criteria: Evaluation of Full-Depth Reclamation for P-8 Aircraft Operations

Abstract: A structurally failed asphalt pavement section was reconstructed to investigate the full-depth reclamation (FDR) technique. The full-scale FDR pavement section consisted of six different test items containing different FDR material blends, a minimum asphalt layer thickness (i.e., 2 in. and 3 in.), and FDR-surface pavements (i.e., asphalt-surfaced and unpaved pavements). The FDR layers were stabilized with a combination of an asphalt emulsion and Portland cement. A heavy vehicle simulator was employed to simulate the loading conditions of the P-8 Poseidon aircraft. The performance of the full-scale pavement section before and after the FDR reconstruction was compared. The FDR technique was satisfactorily implemented to restore the structural capacity of a failed asphalt pavement. The pavements with FDR layers yielded at least two times more allowable passes than the conventional pavements. The FDR-surface pavement sections also demonstrated structural competency to support the expedient operation of heavy aircraft. The performance data generated from this project must be implemented to improve current practices in the design and evaluation of airfield asphalt pavements containing an FDR layer.

26 Jun 2025

Preliminary Study for Rapid Ground Stabilization

Abstract: The Army has a need to rapidly repair heavily damaged low-volume roads. This report describes the literature review, laboratory study, and preliminary technology evaluation for potential rapid road rehabilitation materials and equipment. The objective was to identify and evaluate equipment, materials, and techniques for rapid road repair. This phase of the study focuses on rapid stabilizers that, when added to native soil, could improve bearing capacity. Lightweight equipment and attachments were assessed for their ability to effectively excavate and place geomaterials. Several commercial soil stabilizers were identified that could meet strength requirements. Equipment attachments for a compact track loader were deemed most suitable for executing rapid repairs.

18 Jun 2025

Evaluation of Commercial Cementitious Rapid-Setting Materials and Testing Protocol for Repairing Airfield Spalls

Abstract: The Pavement Repair Material Certification Program assists the US Air Force Civil Engineer Center by executing independent testing on select commercial cementitious proprietary products to repair partial-depth spalls in airfield concrete pavements. The selection of cementitious rapid-setting repair products can be difficult for military personnel considering the number of commercially available proprietary products. Too often, many product manufacturers highlight product strengths while masking undesirable properties. The purpose of this research was to evaluate selected commercially manufactured cementitious products through a series of laboratory testing protocols. These protocols were established to aid airfield managers and repair teams in selecting optimal airfield pavement spall repair materials by maintaining a database of approved products. Under the program, approximately four to six repair products are tested annually. This report presents the laboratory test methods and results of cementitious rapid-setting repair products tested at the US Army Engineer Research and Development Center from 2018 to 2022. The report also evaluates the overall test methods for assessing a material’s suitability for airfield spall repairs. Using the laboratory evaluation, eight products were identified as compatible for partial-depth airfield pavement concrete spall repairs.

16 Jun 2025

Evaluation of Tekcrete Fast for Airfield Pavement Repairs

Abstract: Tekcrete Fast is a deployable, high-strength cementitious product with rapid bonding force that was initially developed to provide stability for structures damaged by seismic activity and explosives. The product was evaluated by researchers at the US Army Engineer Research and Development Center for its ability to execute necessary force projection and resilient infrastructure repairs for the US military without major negative impacts to the mission. Full-scale testing of the rapidly emplaced calcium-sulfoaluminate (CSA) concrete product was completed to identify the sustainability and strength of the material with military aircraft traffic. The CSA concrete mixture was designed for dry-mix shotcrete applications and adapted to be placed conventionally (cast-in-place) using a portable skid steer concrete mixer. This report presents a technical evaluation of the field performance of full-depth concrete repairs conducted using the cast-in-place Tekcrete Fast material in a portable concrete mixer. Passes-to-failure rates for each repair were determined using an F-15E load cart. Results indicated that Tekcrete Fast meets the military’s criteria for being an expedient pavement repair solution.

12 Jun 2025

Evaluation of Commercial Cementitious Rapid-Setting Materials and Testing Protocol for Repairing Airfield Spalls: Material Testing Results for 2023 and 2024

Abstract: The Pavement Repair Material Certification Program assists the US Air Force Civil Engineer Center by executing independent testing on select proprietary commercial cementitious products used to repair partial-depth spalls in airfield concrete pavements. Selecting cementitious rapid-setting repair products can be difficult for military personnel because of the high number of commercially available products. Too often, product manufacturers highlight product strengths while masking undesirable properties. The purpose of this research was to evaluate selected commercially manufactured cementitious products through a series of laboratory testing protocols. These protocols were established to aid airfield managers and repair teams in selecting optimal airfield pavement spall repair materials by maintaining a database of permitted products. Under the program, approximately four to six repair products are tested annually. This report presents the laboratory test methods and results for cementitious rapid-setting repair products tested at the US Army Engineer Research and Development Center in 2023 and 2024. These test methods and results were evaluated for their ability to assess a material’s suitability for airfield spall repairs. No products were identified as compatible with partial-depth airfield pavement concrete spall repairs.

27 May 2025

Naval Expeditionary Runway Construction Criteria: Evaluation of Reduced Flexural Strength Portland Cement Concrete under P-8 Traffic

Abstract: A full-scale airfield pavement test section was constructed and trafficked by the US Army Engineer Research and Development Center (ERDC) to investigate the impact of substandard flexural strength portland cement concrete (PCC) on the pavement structural support requirements for the P-8 aircraft. The substandard pavements were representative of those that may be encountered in remote locations where there may be a lack of locally available competent materials, standard construction equipment, or a skilled labor force. The test section consisted of two PCC surface thicknesses that closely matched those evaluated in previous studies utilizing standard-strength PCC. The test items were trafficked with a dual-wheel P-8 test gear on a heavy-vehicle simulator. The outcomes of the trafficking test showed a significant reduction in PCC pavement performance resulting from the reduction in flexural strength. Further, a comparison of observed performance to current pavement design and evaluation procedures suggested that current procedures may be overly conservative and may exceed a level of conservatism appropriate in a contingency environment.

23 May 2025

Laboratory and Full-Scale Testing of JETCON JC400 Rapid-Setting Concrete Repair Materials for Crater Repairs

Abstract: The DoD currently utilizes rapid-setting concrete (RSC) for a variety of applications, including capping airfield pavement repairs, to limit closure time. Laboratory and field criteria were previously developed for certifying proprietary products for use in various sizes of repairs to ensure performance under aircraft loads. A few certified products have been added to the qualified products list for larger repairs, but none are manufactured in the region near the Korean peninsula. To address this issue, a candidate Korean product (JETCON JC400) was evaluated via the established laboratory and full-scale testing protocol. One large (i.e., 15 ft × 15 ft) repair and two small (i.e., 8.5 ft × 8.5 ft) repairs were conducted and trafficked with simulated F-15E aircraft traffic. JETCON JC400 met all criteria; therefore, the authors recommended adding it to the US Air Force Qualified Products list for large and small pavement repairs. The material is compatible with all volumetric concrete mixers currently in the DoD inventory and has many other potential applications.

5 May 2025

Assessing a Mobile Microgrid to Support Electric Vehicle Charging Stations on Army Installations

Abstract: Supplying reliable, off-grid power is critical for transitioning the Army’s fleet to zero carbon emitting vehicles. At the same time, vehicle charging and mission support equipment may require increased electrical loads than currently experienced at Army installations. Other decarbonization initiatives require clean sources of energy. Using microgrids powered with renewable electricity generation systems is a viable, independent solution for powering electric vehicles. Yet, there is a need to fill information gaps in the performance of these systems for realizing sustainable and resilient energy. The goal of this project was to increase the Army’s energy resilience by reducing reliance on the utility grid by using a compact and mobile microgrid that functions as an EV charging station. In this study, a trailered, mobile microgrid that integrates solar panels, a diesel generator, and batteries is evaluated based on performance under varying conditions. The energy generation capabilities are documented and evaluated for capabilities for powering electric vehicles. The outcomes of this research are the advancement of energy resiliency and the addition of performance in temperate and cold regions to the knowledge base. It is also anticipated this research may be leveraged to facilitate power independence and further support decarbonization efforts.