From Material Patching to Structural Systems: A Comprehensive Review of Pothole Repair Technologies

Abstract

The world\'s road infrastructure is getting worse faster than ever since more vehicles are on the road and the weather is changing a lot. In this case, potholes have become a very important failure criterion. The existing repair methods just fix the surface of the road, which is not the core problem. This gives the road infrastructure a temporary fix. Because of this, the repair methods often cause things to happen again and moisture separates. The goal of this review is to put together the most recent changes in how to fix pavement. The review covers new developments in standard cold mix materials, polymer-modified materials, fiber-based materials, and modular structural materials. Some of the most important changes are the use of reactive asphalt to get traffic moving again right away after repairs, ultra-high performance concrete panels for road repairs because they can hold more weight, and polymer-based materials for fixing pavements. Multi-criteria decision analysis and lifecycle costing are also used to look at the repair methods. A notable research deficiency is evident as the existing studies predominantly concentrate on altering materials rather than systems.

Introduction

Pothole-induced pavement degradation is a major global problem that affects road safety, increases vehicle operating costs, and creates economic burdens for both road users and governments. Potholes form due to pavement fatigue, moisture infiltration, traffic loads, and environmental factors such as freeze-thaw cycles. Traditional repair methods like cold mix asphalt and hot mix patching are often temporary, prone to moisture damage, weak bonding, and recurring failures.

To overcome these limitations, researchers are exploring advanced materials and repair systems. Polymer-based materials such as HDPE-modified asphalt, geogrids, geotextiles, epoxy resins, and polyurethane improve pavement strength, flexibility, moisture resistance, and durability while also supporting sustainability through the use of recycled materials. Modular and prefabricated pavement systems, including precast concrete panels and interlocking blocks, enable faster installation, improved quality control, reduced traffic disruption, and longer service life.

Modern evaluation methods such as Falling Weight Deflectometer (FWD) testing, wheel tracking, numerical modeling, and skid resistance analysis are used to assess pavement performance and structural integrity. Additionally, scalable manufacturing techniques like compression molding and injection molding are essential for producing polymer-based pavement systems efficiently for large-scale applications.

Overall, the review highlights the need to shift from conventional short-term repairs to innovative, durable, sustainable, and rapidly deployable pavement repair technologies.

Conclusion

This review paper emphasizes the need to transition from temporary, function-based pavement maintenance models toward a structural intervention approach that addresses the challenges posed by increasing vehicular loads and changing climatic conditions. While high-performance rapid repair methods provide immediate solutions to pavement distress, structural solutions such as high-density polyethylene panels offer more sustainable long-term performance through improved load distribution and a reduction in repetitive maintenance cycles. A significant research gap remains in understanding the interaction between repair materials and the overall pavement structure, highlighting the importance of validating laboratory findings through comprehensive field evaluations rather than relying solely on isolated experimental results. Future research should therefore focus on developing smart, commercially viable repair systems that integrate self-healing polymers with embedded microsensors, enabling the establishment of a practical and sustainable framework for the long-term resilience of global road infrastructure.

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Copyright

Copyright © 2026 Berlyn R, Akalya S, Ahalya S, Jacob Samuel R, Anita S. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.