Jay Behnke, P.E.S.T.A.T.E. Testing L.L.C.

FHWA Tollway National Open House,August 20, 2013

Sustainable Roadway Materials for the I-90 Project

Tollway – Building GREEN Waste – reduction work zone Striving to “eliminate construction waste

that is traditionally sent to landfills for disposal”

Recycling 100% of In Place Materials “Recycled Concrete, asphalt and other

materials, including roof shingles and tires will be used as base materials, backfill and in new pavements.”

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http://www.illinoistollway.com/construction-and-planning/environmental-initiatives/building-green-roadways

Recycling Plan in Profile

Existing Pavement

Proposed Pavement

Black Rock Concrete and for Capping Agg.

PGE or RCA in Black Rock Concrete

Subgrade Granular Embankment, SpecialLimited offsite disposalModification my be necessary

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Part 1:

REMOVE EVERYTHING!

…..but keep it.

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Salvaging Existing Asphalt: Milled Asphalt will be recycled into

one of the following: PGE

Mechanically blended with Crushed Concrete for use in lower lift

Capping Aggregate 3” lift over PGE

Component of WMA Fine FRAP / Coarse FRAP 3” Stabilized Sub Base Shoulders

Component of Black Rock Concrete Lower Lift of Composite PCC

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The GOOD, the BAD and the UGLY

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Salvaging Existing Concrete: Concrete will be recycled into Porous Granular

Embankment (PGE) in one of the following ways: Break in place (Rubblized)

Difficult to achieve target gradation Mobile crushers

Best Option Off Site crushing

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Production of Crushed Concrete Engineer will approve removal

and stockpile method. Stockpile pads are required for

stationary crushers. Contamination from existing

base - not acceptable. May be used for subgrade

treatments. Mobile Crushers PGE Production

Stationary Crushers Composite Pavement

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Salvaging Existing Granular Material: Remove the Granular Bank Run and move into one of

the following locations for future use: Stockpile Windrow Off Site

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Sub Base Widening Tollway is adding a lane

and shoulder Widening needed Existing ditches are used

for widening Remove topsoil and

stockpile separate

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Grade changes throughout the I-90 Corridor

Additional Hurdles:

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Part 1 A:

ALL GONE!

…..let’s start new.

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Create a Working Platform: Determine Immediate Bearing Value (IBV) of Sub Base IBV ≥ 8.0 Disc Dry

Moisture content≤120% Air dry top 8” for 3 consecutive days

Compact ≥95% relative compaction

IBV < 8.0 Need to stabilize the base

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Disc-ing In-Place Material (IBV ≥ 8.0)

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Subgrade Stabilization Treatments (IBV < 8.0)

Lime Stabilization Fly Ash Stabilization

Clay Soils Granular Soils

FLY ASHLIME

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Lime or Fly Ash Modification

Contractor will elect to use either Lime or Fly Ash

Collect soil samples to be modified

Send samples to an accredited lab for a Soil Modification Mix Design

Must be approved by the Tollway

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Fly Ash Soil Stabilization I-90 – Jane Addams Memorial Tollway is mostly Granular Soils Fly Ash Stabilization @ 8% rate Modified 12 inches

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Lime Soil Stabilization

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Working Platform is Complete

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Part 2:

PUT EVERYTHINIG BACK

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Start adding back the Recycled Materials

Granular Embankment Special

6” Lift

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Placing PGE over the Granular Embankment Special

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Porous Granular Embankment

PGE

6” of PGE 5” Max Size for PCC 4” Max Size for RAP

Tollway allows more RAP than IDOT (50% max RAP) Contaminated RAP – not

allowed Mechanical blending is

required if using RAP

Feed material only from approved source Unknown material needs re-

certification

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PGE

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Capping Aggregate

3” Lift over PGE

Materials from approved source

CA6 gradation if it’s crushed concrete

”C” Quality or better 100% passing 3” max. for

RAP (must be well graded)

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Hwy 23 – Looking East (Capping Aggregate)

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Ready for WMA? …not quite.

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Stabilized Base

WARM MIX ASPHALT 3” Stabilized Base of WMA Up to 65% ABR allowed

with Category 1FRAP PG58-28

What is WMA? Chemical admixtures or

water “foam” Modify viscosity of asphalt

cement (binder) At lower production and

laydown temperatures, acts like “normal” HMA.

After slightly longer “curing”, has physical properties similar to “normal” HMA.

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Jane Addams Tollway WMA, FRAP, RAS

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WMA – stabilized base

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Composite Pavement – 2 Lift Pavement

Black Rock PV Lift

Lower Lift only From 8 ¼” to 9” Includes RAP from Milling

Process Lower Quality Virgin

Aggregates

Top Lift only 3” Virgin Only

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PCC Production Trial Batching Test Section Two Plants are required Paving Train Different between

contractors

Dowel Baskets or DBI are accepted

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Composite Pavement

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Black Rock Concrete

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PCC Placement

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PCC Placement

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PCC Placement

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Difficult Staging area – requires unique solution

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Millions of $’s Saved on I-90Avg. bid price based on 2006 - 2009 Single Lift JPCP Projects Approximately 1,188,086

sq. yds. of 12” JPCP placed on I-294 and I-88

Average low bid price = $56.37 / SY

Avg. bid prices received on 6 2013 jobs for Composite JPCP > 750,000 sq. yds. to be built

on I-90 in 2013 11.25” Composite JPCP -

$40.30/SY avg. of all bids 12” Composite JPCP -

$45.92/SY avg. of all bids 13” Composite JPCP -

$49.70/SY avg. of all bids

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THANK YOU40