November 2005
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Maximum Asphalt

Alabama’s I-20 Project:
Rubblizing on a Grand Scale
Rubblizing, a new lane, and concrete median barriers
 make up key project elements.

by Chuck MacDonald

A massive road-building project on I-20 reconfigures a portion of the major thoroughfare between Birmingham, Alabama, and Atlanta, Georgia. The current piece of the project has contractors rubblizing the old concrete pavements, squeezing in a new inside lane, and installing concrete barrier rails in the median. All of this activity is taking place on one of the busiest roads in the state. What the contractors and the planners at the Alabama DOT are attempting is like adding a new kitchen and bathroom to your house while serving Thanksgiving dinner for out-of-town guests.

But it’s all for a good cause: safety of the traveling public. 

“This interstate carries a heavy traffic load, with more than 40% of it being trucks,” said Brian Davis, pre-construction engineer for the Birmingham division of the Alabama DOT. “Traffic crossing over the median frequently happened at high speed and invariably resulted in death or very serious injuries.” 

Not only had the road become dangerous, but drivers, contractors, and agency personnel also agreed that the road was in deplorable condition. “This concrete pavement had been rehabilitated once or twice, but was beyond patching,” said Larry Lockett, materials and test engineer at the DOT. “We analyzed the cost of an unbonded overlay of concrete or rubblization of the highway and overlaying it with flexible pavement. We found the cost to rubblize and overlay with asphalt was generally 15 to 20% less.”

Project basics

The current projects underway call for contractors to add a 12-foot-wide inside lane in each direction to the interstate, transforming the highway from four to six lanes. Drainage systems needed to be constructed and the concrete barrier rail installed to eliminate crossover accidents.

Work-zone safety is an issue, as always, with the busy traffic being shifted first to an outside shoulder while construction proceeded. Often, workers were only 3 feet away from the speeding traffic. Alabama state troopers were regularly on site to help control traffic speed. About 30% of the work was done at night.

Two contractors are each currently doing 4-mile stretches of the road, in the area of the intersection of U.S. 231 in St. Clair County. The new road will be SMA, as are nearly all Alabama interstate projects. The 4.5 inches of SMA mix contains both polymers and fibers. Underneath the SMA layers is Superpave binder on top of the rubblized concrete. The 11 inches of new pavement will be topped with a thin layer of open-graded friction course to reduce splash and spray for the driving public. 

Contractors laid the top 4.5 inches of stone matrix asphalt for the Interstate 20 project. They will later put down a layer of open-graded friction course to reduce splash and spray for the driving public.

Contractors placed a total of 11 inches of new pavement for the project, including the 4.5 inches of stone matrix asphalt on top.
Rubblization was a key element in contractors’ strategies to complete the project on time and within budget.
Interstate 20 between Birmingham, Alabama, and Atlanta, Georgia, carries a heavy load of truck traffic. At this stage in the construction, contractors have paved a new lane and shoulder (left) and are preparing to pave a new lane and shoulder (right). A new concrete barrier rail, complete with drainage inlets, has been built to reduce crossover accidents.

The current projects follow on the heels of similar work done on I-20. These and the earlier projects had a 40-foot median to work with in building the new lanes and inserting the concrete barrier rails. The 40-foot median allowed for the additional lanes to be constructed with inside widening only, which simplifies the design and construction dramatically. However, there remained one segment that was approximately 7-miles long that had a 30-foot median.

The 30-foot median did not allow adequate room to fully construct the barrier wall and the additional lanes, so this segment was divided into two phases of construction. The first phase closed in the median with the required drainage improvements and concrete barrier to provide quick relief from the crossover accidents. This phase of construction is now complete and open to traffic. The barrier wall is in place and the four lanes are pushed to the inside. 

Phase 529

The second phase, which is currently under final design, will add one lane to the outside in each direction and is targeted to be let to contract in early 2006. Once this phase is complete, I-20 will be a full six lanes from Birmingham to approximately a half mile west of the St. Clair/Talladega County line. 

“Because of the urgency of the safety issues, our director wanted these projects put on a fast track,” said Davis. “So as soon as the planning was complete, the money was allocated and the projects were let. The contractors are having success in meeting some tight schedules.”

The current road-building projects are being coordinated by APAC Southeast Inc., based in Birmingham, Alabama, and Good Hope Contracting, Cullman, Alabama.  These contractors are building two sections of road that are approximately 4-miles long each. The bridge-widening part of the project is being handled by Alabama Bridge of Pelham, Alabama; and the rubblization was done by RMI, of Tulsa, Oklahoma.

As with most projects of this size and complexity, teamwork is essential. Good Hope’s project began by July, 2004. The three lanes are supposed to be fully opened to traffic by press time.

“We’ve worked with excellent subcontractors,” said Good Hope’s Vice President John Brown. “At the halfway point of our allotted time, we had completed 71% of the work.”

Good Hope and APAC Southeast Inc. were responsible not only for the road building, but also for ensuring proper drainage between the east- and west-bound lanes of the highway. Drainage inlets were constructed to collect the water and route it away from the traffic.

The drainage inlets were constructed to fit with an unusual concrete barrier rail. The usual jersey barriers are about 32-inches high, but contractors were required to add another 22 inches of concrete to make the barriers high enough to reduce the glare of truck lights into the other lanes, as well as all but eliminate rubbernecking of motorists slowing down to watch anything unusual happening in the opposing lanes.

“The rubblizing process also went smoothly,” said Jeff Janeway, APAC Southeast  Inc.’s area manager for Birmingham-Tuscaloosa. “By rub-blizing the concrete, we saved time and money. There’s no  way we could have done the job with that kind of timeline without rubblizing.” 

By mid-August, APAC’s project was 85% complete. When the company is finished, it will have constructed 1,800 feet of barrier rail and used some 300,000 tons of asphalt. APAC, Good Hope, other contractors and agency personnel at the DOT will have contributed to an even more important, though unknown, statistic. “The additional lane will help with the traffic flow,” said Janeway, “but we will also have made the road a lot safer. There’s no telling how many lives this project will have saved.”


Chuck MacDonald is the Director of Communications for the
National Asphalt Pavement Association in Lanham, Maryland.

Reprinted from Better Roads Magazine
November 2005

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