This paper describes part of the author's continuous research effort in developing a rational and comprehensive methodology for the design and evaluation of highway pavements. Initially, some attention is paid to the most sophisticated non-destructive testing (NDT) system currently available for highways. A mechanistic computer design model (PC-DEF), based on finite element method, is then presented together with the proposed refinements in its non-linear analysis approach. A back-analysis method for the determination of in-situ material elastic moduli in pavement structures, based on optimisation of least squares deflection functions, is formulated into the model DEFBAC. The paper goes on to describe how in-situ back-analysed moduli can be used to predict 'in-service' pavement fatigue and remaining life based on NDT deflection measurements. Finally, the paper concludes by presenting a simplified problem based example that illustrates the essential steps for the evaluation and rehabilitation design of an actual pavement using DEFBAC. The case study covers a typical NDT investigation conducted to identify the work needed to rehabilitate or reconstruct a section of a major trunk road.

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