For over 40 years, airport management has relied on the Pavement Classification Number (PCN) system to evaluate runway strength. However, the Federal Aviation Administration (FAA) has transitioned to the Pavement Classification Rating (PCR), a more precise, data-driven system that better reflects an airport’s actual aircraft operations, load distributions, and subgrade conditions. In this article, we delve into what a PCR is, the process of determining PCR, and why airports should evaluate their pavements for PCR now while the update is new.
A real-world example of this transition can be seen at a recent airport project in New England. A PCR rating consists of five key components, each offering insights into pavement capacity. Before its upcoming runway reconstruction project, the main runway at the airport had a PCR of 320/F/B/X/T, meaning:
✔ 320 – The maximum Aircraft Classification Rating (ACR) the pavement could support under standard conditions.
✔ F – Flexible pavement, primarily composed of asphalt.
✔ B – Moderate-strength subgrade, affecting load distribution.
✔ X – High allowable tire pressure, ensuring compatibility with modern aircraft.
✔ T – The rating was determined using the technical method, based on FAARFIELD analysis.
While this rating was sufficient for daily operations, larger aircraft like the Boeing 737-800 were becoming more frequent, pushing the pavement’s load limits. The subgrade category (B) and a Cumulative Damage Factor (CDF) of 10.850 indicated that continued high-traffic operations could accelerate wear. CDF is a measure of pavement fatigue, with higher values indicating greater cumulative stress and potential for failure. A CDF of 1.0 typically represents the pavement reaching its design life, while values exceeding this threshold, such as 10.850, suggest significant overuse and an increased risk of premature deterioration.
To address these challenges, the airport initiated a Full-Depth Reconstruction of the runway pavement. The upgraded pavement of 4 inches of P-401 asphalt, 5 inches of P-403 asphalt, 6 inches of P-209 crushed aggregate base, and 6 inches of P-154 subbase resulted in a new PCR of 500/F/A/T, resetting the CDF to 0.00. This upgrade enhances pavement strength, extends service life, and ensures compliance with FAA pavement management requirements.
The Process of Determining PCR: Challenges & Considerations
Determining an airport’s PCR requires analyzing both Aircraft Classification Rating (ACR) and subgrade strength, each with its own complexities:
✔ ACR Complexity – ACR varies by aircraft type, gear configuration, and tire pressure, requiring accurate traffic data to determine the actual fleet mix.
✔ Subgrade Variability – The strength of the soil, assessed through geotechnical testing, influences how loads are distributed through the pavement structure and affects overall pavement longevity. Variability in soil conditions or discrepancies in geotechnical data can lead to differences in PCR calculations, impacting pavement management decisions.
Our team recently assisted Portsmouth International Airport at Pease in New Hampshire, Tweed-New Haven Airport in Connecticut, as well as Groton-New London and Bradley International Airports in Connecticut in determining their PCR values using FAA’s FAARFIELD 2.0 software. By analyzing aircraft fleet mixes, pavement composition, and subgrade conditions, these airports obtained accurate PCR ratings that provide a clearer understanding of pavement capacity and ensure FAA compliance.
Why Airports Should Act Now: The transition from PCN to PCR is more than just a regulatory update; it’s an opportunity to optimize pavement management, reduce maintenance costs, and extend infrastructure longevity. With the FAA’s deadline of November 28, 2025, all Part 139 certificated airports must update their PCR. Acting now ensures compliance while allowing airports to proactively manage their pavement assets, improve safety, and make data-driven infrastructure decisions.
✔ Optimize operational planning
– Understand true pavement capabilities and avoid unnecessary restrictions.
✔ Enhance FAA compliance
– Ensure eligibility for funding and align with regulatory standards.
✔ Make data-driven investment decisions
– Plan infrastructure upgrades based on real pavement conditions, not assumptions.
PCR provides airport management with a more precise understanding of pavement strength, helping extend runway service life, reduce unexpected repairs, and optimize maintenance budgets.
For airports yet to update their PCR, now is the time. Our team specializes in guiding airports through the transition, ensuring accurate assessments and FAA compliance.
Is your airport ready for the future of pavement management? Contact me today to learn how we can support your PCR evaluation and planning needs.
