Pavement roughness monitoring is critical for infrastructure management, but conventional automated profiling systems require substantial capital investments, making them inaccessible to limited-budget transportation agencies. This paper introduces a low-cost system combining Inertial Measurement Unit (IMU) and Pulsed Coherent Radar (PCR) technologies through sensor fusion. The approach captures vehicle dynamics via the IMU and pavement surface profiles via the PCR, using frequency-domain processing to isolate true pavement roughness from vehicle-induced motion. Comprehensive validation across twelve road segments and 216 test configurations demonstrates strong performance: MAPE below 9 % and R2 exceeding 0.96 compared to reference measurements. A multi-stage optimization framework integrating Sequential Model-Based Optimization algorithm achieves 80–88 % accuracy improvements through systematic parameter calibration. The complete system costs $214 USD, providing a cost-effective solution for IRI estimation. A user-friendly graphical interface enables practical deployment by non-technical personnel. This approach enables broader adoption of automated pavement monitoring by agencies with limited budgets.
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