Introducing an Innovative Prefabricated Thin Rolled Asphalt Preservation Patch Technology for Asphalt Pavement Maintenance Management

Asphalt pavements are subjected throughout service life to various factors, including environmental conditions, repeated traffic loading, and changes in material properties, which gradually lead to distresses such as cracking, rutting, and surface deterioration. Since the application of new overlays and structural rehabilitation measures requires considerable time and financial resources, preventive maintenance techniques and localized repair solutions have attracted increasing attention as cost-effective and efficient alternatives. In this study, a novel technology referred to as a Thin Prefabricated Rolled Asphalt Preservation Patch is introduced and evaluated. This system enables rapid installation, cold application, and immediate traffic reopening without the need for lane closures. The development process involved the design and fabrication of several experimental prototypes, optimization of bituminous formulations, incorporation of reinforcing polymer fibers, and refinement of a multilayer structural configuration, ultimately resulting in a product with adequate strength, flexibility, and durability. Key characteristics of the developed patch include its low thickness, light weight, excellent resistance to water penetration, strong adhesion to pavement surfaces, and ease of installation. The results of laboratory performance tests and field implementation on the Qazvin–Karaj Expressway demonstrated that the proposed technology performs satisfactorily under heavy traffic loading, thermal stresses, and adverse environmental conditions. The findings suggest that the developed patch can serve as an effective solution for localized pavement rehabilitation, preventive maintenance activities, and emergency repair operations. The adoption of this technology offers significant potential for extending pavement service life, reducing maintenance costs, and improving the efficiency of transportation infrastructure management.