Reprinted with permission from F.W. Dodge MIDWEST CONSTRUCTION.

East-West Tollway (I-88) Pavement Rehabilitation (Rubblization)

DeKalb and Kane Counties – Illinois State Toll Highway Authority

Faced with the need in the future to rehabilitate significant sections of the aging Tollway system, the Illinois State Toll Highway Authority retained Beling Consultants for the design and construction management of an innovative rehabilitation pilot project for the EastWest Tollway (I-88). Beling was assisted by Mr. Marshall Thompson, P.E., Professor Emeritus of The University of Illinois. Located within the I-88 research corridor, between IL Route 41 and Peace Road, the project was divided into two, 2-mile sections with different base conditions.

Rehabilitation was accomplished under the project management of Curran Contracting Company, using a new technique called "Rubblization." The existing pavement consisted of 14" thick concrete, which is the first known attempt in Illinois to rubblize a pavement of this thickness, where the existing deteriorating concrete pavement is broken up into fragments of from 6" to 9" inches or smaller. Using a three-unit sequence, the process required a high-impact breaker which created the initial break-up of the original concrete surface. Next, a heavy Z-roller further crushed and broke up the concrete into finer particulate. Finally, a smooth- surface heavy vibratory roller finished the breakage, and compacted the surface in-place. The reprocessed concrete base was then overlaid with asphalt.

The two sections of pavement will be evaluated and studied for the next several years to determine the effectiveness and ability of rubblization to be used throughout the Tollway system. The 188 rubblization project was completed at a construction cost of $3,830,000 -- nearly 25% less then conventional rehabilitation techniques were estimated to be. The project was constructed in 3 months -- a time savings of 3 months. This resulted in a safer, less disruptive construction project for the traveling public, as well as significant cost savings.