Concrete Composite Pavement Construction. Steven L. Gillen, Manager of Materials Illinois Tollway National Open House August 20, 2013

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1 Concrete Composite Pavement Construction Steven L. Gillen, Manager of Materials Illinois Tollway National Open House August 20, 2013

2 Congestion-Relief Program Lessons Learned Nearly Completed 2

3 Tollway Requires 100 Percent of Concrete and Asphalt Pavements with Reconstruction In Base Aggregates In New Asphalt Mixes 3

4 Innovations Adopted Fractionated RAP (FRAP) Recycled Asphalt Shingles (RAS) 4

5 Decreased Cost of High-Traffic Volume Premium SMA Surface Mixes $114/ton in 2008 and 2009 $111/ton in 2010 $91/ton in

6 Big Tollway Savings on Little Research Investment Relative to Asphalt Recycling $30,000,000 $25,000,000 $20,000,000 $15,000,000 $10,000,000 Research Investment Savings $5,000,000 $- GTR FRAP RAS WMA 6

7 Desire for Similar Savings with Concrete Brings Back Composite Pavements 7

8 Average Price from Congestion-Relief Projects Average bid price based on single-lift JPCP projects Approximately 1,188,086 square yards of 12 JPCP placed on Tri-State Tollway (I-294) and Reagan Memorial Tollway (I- 88) reconstruction and widening projects Average low bid price = $56.37 / square yard 8

9 Bid Prices for Composite Pilot Job Bid Prices for 11.5 composite (37,545 square yards one contract) $60.10 / square yard average of all bidders (six) $59.00 / square yard for single low bidder 9

10 2012 Engineer s Estimate For JPC composite $61.00 / square yard For 11.5 JPC composite $63.00 / square yard For 12 JPC composite $65.00 / square yard For 13 JPC composite $70.00 / square yard 10

11 Actual Prices for 2013 and 2014 Massive Placements of JPCP Bid prices for 2013 construction of JPC composite (637,429 square yards five contracts) $40.30 / square yard average of all bids (24 total) $38.43 / square yard average of all low bidders (five) Bid prices for 2014 construction of JPC composite (685,243 square yards five contracts) $40.42 / square yard average of all bids (15 total) $38.15 / square yard average of all low bidders (five) 11

12 Actual Prices for 2013 and 2014 Massive Placements of 12 JPCP Bid prices for 2013 construction of 12 JPC composite (136,960 square yards two contracts) $45.92 / square yard average of all bids (13 total) $45.69 / square yard average of all low bidders (two) Bid prices for 2014 construction of 12 JPC composite (138,336 square yards two contracts) $42.00 / square yard average of all bids (five total) $43.15 / square yard average of all low bidders (two) 12

13 Actual Prices for 2013 and 2014 Massive Placements of 13 JPCP Bid prices for 2013 construction of 13 JPC composite (33,621 square yards one contract) $49.70 / square yard average of all bids (seven total) $54.00 / square yard average of single low bidder Bid prices for 2014 construction of 13 JPC composite (35,862 square yards one contract) $47.50 / square yard average of all bids (two total) $48.00 / square yard average of single low bidder 13

14 What Contributed to Lower Prices? As a result of current design Reduced portland cement market costs Lower portland cement quantity with ternary mix Slightly reduced aggregate costs with black rock recycling Eliminate slip-form paver 14

15 What Contributed to Lower Prices? Other Factors Reduced number of dowel bars across transverse joints Application of dowel bar inserters with two-lane paving 15

16 What Contributed to Lower Prices? Other Factors Reduced maintenance of traffic costs Counterflow MOT in the past Currently, all traffic on one side of the median 16

17 What Contributed to Lower Prices? Other Factors State of current economy and lack of infrastructure construction 17

18 What More Can Be Done Through Composites to Improve Sustainability But Not Lower Costs? Use smog-eating cements (titanium oxide) in top lift Use premium coarse friction aggregates in top lift with broomed exposed aggregate surface texture to control tire noise and improve safety 18

19 What More Can Be Done Through Composites to Improve Sustainability And Lower Costs? Use lower-quality coarse aggregate in bottom lift Use lower quality coarse FRAP in bottom lift Replace natural sands with manufactured sands Start stockpiling certified RCA aggregates Prove that two mixes can be produced out of one plant 19

20 20 THANK YOU