Permeable Polyurethane Grouting Method for Rapid Pavement Repair: Full-Scale Model Testing Case and Numerical Simulation

To address pavement defects such as cracking and loosening caused by increased highway traffic volume and heavy-duty vehicles, and to enhance structural load-bearing capacity and service life, a novel high-permeability, strong-bonding polymer grouting material has been developed for pavement rehabilitation. This study investigated the deflection characteristics and mechanical behavior of pavement structures before and after permeable polymer grouting repairs through full-scale model testing. A pavement model was developed to simulate pavement response under dynamic loading. Research findings indicate that permeable polymer grouting effectively improves the condition of damaged road surfaces. Surface layer index SCI, base layer index BDI, and subgrade index D8 all showed significant reductions. This confirms that polymers not only effectively consolidate fragmented base layers but also enhance the overall stiffness of the surface layer and subgrade through permeation and diffusion. The numerical simulation results closely align with the measured data trends, validating the reliability of the established model in predicting repair effectiveness. These findings provide a theoretical basis and practical reference for the engineering application of polymer grouting repair technology and the prevention and control of structural defects.