Sustainable Roadway Materials for the I-90 Project

Transcription

1 Sustainable Roadway Materials for the I-90 Project Jay Behnke, P.E. S.T.A.T.E. Testing L.L.C. FHWA Tollway National Open House, August 20, 2013

2 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. 2

3 Recycling Plan in Profile Black Rock Concrete and for Capping Agg. Existing Pavement Proposed Pavement PGE or RCA in Black Rock Concrete Subgrade Granular Embankment, Special Limited offsite disposal Modification my be necessary 3

4 Part 1: REMOVE EVERYTHING!..but keep it. 4

5 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 5

6 The GOOD, the BAD and the UGLY 6

7 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 7

8 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 8

9 Salvaging Existing Granular Material: Remove the Granular Bank Run and move into one of the following locations for future use: Stockpile Windrow Off Site 9

10 Sub Base Widening Tollway is adding a lane and shoulder Widening needed Existing ditches are used for widening Remove topsoil and stockpile separate 10

11 Additional Hurdles: Grade changes throughout the I-90 Corridor 11

12 Part 1 A: ALL GONE!..let s start new. 12

13 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 13

14 Disc-ing In-Place Material (IBV 8.0) 14

15 Subgrade Stabilization Treatments (IBV < 8.0) Lime Stabilization Clay Soils Fly Ash Stabilization Granular Soils LIME FLY ASH 15

16 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 16

17 Fly Ash Soil Stabilization I-90 Jane Addams Memorial Tollway is mostly Granular Soils Fly Ash 8% rate Modified 12 inches 17

18 Lime Soil Stabilization 18

19 Working Platform is Complete 19

20 Part 2: PUT EVERYTHINIG BACK 20

21 Start adding back the Recycled Materials Granular Embankment Special 6 Lift 21

22 Placing PGE over the Granular Embankment Special 22

23 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 recertification 23

24 PGE 24

25 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) 25

26 Hwy 23 Looking East (Capping Aggregate) 26

27 Ready for WMA? not quite. 27

28 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. 28

29 Jane Addams Tollway WMA, FRAP, RAS 29

30 WMA stabilized base 30

31 Composite Pavement 2 Lift Pavement Black Rock Lower Lift only From 8 ¼ to 9 Includes RAP from Milling Process Lower Quality Virgin Aggregates PV Lift Top Lift only 3 Virgin Only 31

32 PCC Production Trial Batching Test Section Two Plants are required Paving Train Different between contractors Dowel Baskets or DBI are accepted 32

33 Composite Pavement 33

34 Black Rock Concrete 34

35 PCC Placement 35

36 PCC Placement 36

37 PCC Placement 37

38 Difficult Staging area requires unique solution 38

39 Millions of $ s Saved on I-90 Avg. bid price based on 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 jobs for Composite JPCP > 750,000 sq. yds. to be built on I-90 in 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 39

40 40 THANK YOU