High-performance asphalt with composite-optimized textile reinforcement and integrated sensors

The “HighPerAsphalt” research project is investigating a globally unprecedented, durable, sustainable, and intelligent asphalt construction method for use in road construction, designed to withstand increasing mechanical and climatic stresses over the long term. The objective is to significantly extend the service life of the pavement by using non-metallic textile reinforcement with integrated sensors in the underlying asphalt base course.

High axle loads in road traffic lead to degradation of the asphalt pavement, causing climate- and traffic-induced tensile and compressive stresses in the various asphalt layers, particularly in the lower asphalt base course. These stresses cause microcracks that can spread over time into the surface course. The penetration and subsequent freezing of water in these microcracks promotes the progressive damage of the asphalt pavement, which can lead to the formation of potholes and structural road damage in the long term. To increase the fatigue resistance of the pavement, robust, textile grid structures are to be integrated into the lower asphalt base course as reinforcement. The forces acting on the pavement when vehicles roll over it are absorbed by the non-metallic reinforcement structure, thereby reducing cracking.

To ensure high bond strength between the asphalt mastic and the textile reinforcement structure, the reinforcing filament yarns are to be profiled and processed into a structurally stable, grid-like surface structure. Fiber-based sensors are integrated into the textile reinforcement. These are intended to monitor mechanical loads and traffic conditions. Based on this data, predictions regarding the fatigue behavior of the asphalt base course will be made, and structural maintenance measures will be planned at an early stage.

Other project partners are working on the development of a functional, highly rigid, low-temperature asphalt, a suitable method for incorporating the textile reinforcement into the asphalt, and an AI-based evaluation methodology for the fiber-based sensor system to predict fatigue and monitor loads on the pavement structure or the asphalt base course.

The innovative textile-reinforced pavement structure is intended to extend the service life of the asphalt base course from the current 30 years to 60 years. The goal is to reduce construction and maintenance costs by approximately 32% and_{CO2 emissions} by approximately 40%. The combination of reinforcement and sensor functionality offers significant economic benefits and, for the first time, enables non-destructive, large-scale, data-driven condition monitoring of road infrastructure.

December 2025

In December 2025, the kick-off event for the HighPerAsphalt research project took place at the Institute for Textile Machinery and High-Performance Materials Technology (ITM) at TU Dresden.

Representatives from all project partners—ITM, the Institute of Road Construction (ISS), Johne & Groß GmbH, Wolf Straßen- und Tiefbau GmbH, dresden elektronik ingenieurtechnik gmbh, and TECHiFAB—attended the meeting. Together, they toured the ISS test field and the ITM test field, which features various textile machines.

June 2026

On June 9, 2026, an in-person meeting of the project partners took place at Wolf Straßen- und Tiefbau GmbH. Representatives from ITM, the Institute for Road Construction (ISS), Wolf Straßen- und Tiefbau GmbH, Dresden Elektronik Ingenieurtechnik GmbH, and TECHiFAB came together to plan the next steps in the project.

The focus of the meeting was the detailed preparation of a test section featuring textile reinforcement and integrated sensor technology. Together, the group inspected the planned test site on the premises of Wolf Straßen- und Tiefbau GmbH and evaluated it in terms of the planned implementation.

In addition, the next steps, responsibilities, and key milestones were coordinated. This lays the groundwork for the upcoming construction of the test section.