Automating the repair of potholes using machine techniques and digitally crafted asphalt cartridges

Abstract

Potholes are a major problem on road networks as they reduce driving safety and pavement structural integrity. Current repair methods through filling are labour-intensive and unsafe to workers. This paper presents a new approach to filling potholes with less human intervention. The proposed method adopted a modified 3D printer as the automated pothole filling machine. The machine’s operational paramaters, such as extrusion speed, were optimised to maximise the extrusion rate of asphalt mixtures and enhance the efficiency of the filling process. A new digital design method was developed to quickly select the right aggregate-bitumen proportions for asphalt repair cartridges that meet desired performance standards such as extrusion rate, Marshall stability, Marshall flow, and air void contents. The quality of filled potholes was assessed by measuring the rutting depth. The machine fills exhibited 86% rutting resistance compared to hand fills, indicating its future potential to replace current manual methods.