I-57 PCCP Overlay

Carbondale, Illinois

Illinois Department of Transportation

  • Img 3599 002 Medium
  • Img 3584 Medium
  • Base Plant Medium

Awards:

2016 IDOT Contractor of the Year - Excellence in Concrete Paving 2016 IDOT Contractor of the Year - Work Zone Traffic Control

Services:

  • Highway Construction
  • Concrete Paving / Flatwork
  • Under drains

Project Details

In March 2015, Millstone Weber (MW) was awarded a $30 million contract to complete an unbonded concrete overlay on twenty (20) miles of Interstate 57 in Southern Illinois, which included placement of approximately 400,000 square yards (136,000 cubic yards) of Portland Cement Concrete Pavement in three major stages. Stages 1 and 2 had an intermediate completion date of November 15, 2015. Stage 3 had a completion date of December 1, 2016. To facilitate construction, traffic was switched into an experimental head-to-head configuration separated by delineators with the use of temporary crossovers.

STAGE 1: Construct four (4) miles of Southbound I-57 from July to September 2015
STAGE 2: Construct five (5) miles of Northbound I-57 from September to November 2015
STAGE 3: Construct eleven (11) miles of Southbound I-57 from April to November 2016

This phasing included 39 mainline paving days at a 24' paved width, and 52 should paving days at either 10' or 6' paved widths. MW utilized an on-site concrete batch plant to produce the 136,000 cubic yards of concrete needed to construct the project. Doing so allowed us to tightly control the quality of the concrete mix while allowing flexibility to complete this challenging project. Due to its remote location and large footprint, one of the biggest challenges associated with the project was access. By strategically placing truck turnarounds along the existing roadway and utilizing an IDBI Dowel Bar Inserter on the concrete paver, MW was able to utilize the existing roadway and grade as its haul road for wet batch concrete trucks. Normally, a separate haul road would be constructed to facilitate the movement of trucks between the concrete plant and paving spread. In using these innovative methods, MW was able to minimize project cost and schedule duration, meeting or exceeding all project milestones.

MW's performance on this project earned us the IDOT Contractor of the Year Awards in 2016 for Excellence in Concrete Paving and Work Zone Traffic Control.

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