In a recent project, Midwest Stabilization completed Full Depth Reclamation (FDR) of Maple Street located in Hartford, IL. Midwest Stabilization, located in St. Louis, MO, is a part of the Byrne and Jones umbrella.

“We sit with every client and look at how we can best serve their needs,” says Brett Gaither, business development at Midwest Stabilization. “For this city street, they wanted a better surface than a chip and seal. The original bid was for removal and replacement of the existing road surface with hot mix asphalt. Midwest Stabilization priced that option along with FDR. FDR turned out to be a better solution, better price and by adding the Portland cement it increased the streets stability.”

The Maple Street project began April 2, 2012, and it was completed in eight days. The two-lane road ran 1,600 lineal feet east and west through Hartford crossing over a railroad track. The work was completed in two sections, east of the railroad tracks and west of the railroad tracks.

The existing surface had 2-3 inches of chip seal with a sandy, dirt base. “The dirt and rock base was not stable resulting in base failures,” Gaither says. “There were several potholes and utilities on the road resulting in a bumpy and hazardous ride for residents.”

The first day crews milled 3-4 inches of the chip seal surface. “There was a 3-4 percent crown in some areas, so we had to try and get it down to a 2-3 percent slope by milling off extra material,” says Kevin Klette, project manager. “After that we hauled away the milled material.”

On the second day, the manholes were raised and lowered. The project also had several monitoring wells used for ground water. “We had to frame the monitoring wells and pour new concrete,” Klette says. “We also poured two concrete handicap approaches. The crews ripped out the old concrete sidewalk and gutters installing new ones.”

With some of the sidewalk work carried over to day three, crews also graded the road. The surface was re-graded to even the crown and slope.

After this work was complete, crews focused on the surface west of the railroad tracks. “First, we spread two loads of Portland cement,” Klette says. “Then we took the Wirtgen 2400 reclaimer and tilled the cement into the surface. After that, we added water from a water truck while it was pulverized. Finally, we re-graded the road and compacted it with a smooth drum roller.”

A SS1H asphalt emulsion tack coat was applied to the surface to preserve the Portland cement. “The fog seal locks in moisture and allows the Portland cement to cure,” Klette says. “The western section of the project cured for 72 hours.”

By the sixth day, crews moved to the eastern side of the railroad tracks completing the same stabilization process as the western side of the railroad tracks.

An extra day was given to allow the eastern section enough curing time. “The following day we paved the western section of the project,” Klette says. “We applied 3 inches of asphalt in two lifts consisting of 1.5-inch binder mix and 1.5-inch surface mix. We completed both lifts on the western section of that day.” The same paving work was completed the following day on the eastern side of the project.

Since Midwest Stabilization used FDR it was able to save the city 15 percent. The original bid for Maple Street was remove and replace, and would have required a removal of 12 inches of material with the replacement of 12 inches of material. “With FDR we only had to remove 4 inches of chip and seal surface,” Klette says. “As a result, we were able to save money on trucking, material and labor. We completed the FDR in 8 days while the remove and replace would have taken 16 days.”

Byrne & Jones Construction, the largest commercial asphalt paving company in St. Louis, has launched a new division with a target of $1.5 million in first-year revenue.

The division, called Midwest Stabilization and led by Managing Director Mike Kappel, uses additives to improve the quality of soil before construction. The division also recycles asphalt for use in paved surfaces.

Kappel said the division is being launched to respond to demand from customers for less expensive ways to repair old pavement.

“The economic downturn forced many companies to put off necessary improvements to their properties,” Kappel said. As companies emerge from the recession, they are looking for cost-effective ways to improve their properties, he said.

“The cost to replace a typical parking lot using (Midwest’s) process can be up to 10 percent less than the conventional removal and replacement of the entire pavement structure,” he said.

Midwest uses machinery to pulverize old asphalt that is then relaid as new pavement.

Byrne & Jones, led by President Brian Goggins, produced nearly $21 million in revenue last year. The company employs 70 people.

The new division currently employs five workers originally employed by Byrne, and Kappel said that number is expected to double by the end of the year from new hires.

Joe Schroer, a field materials engineer for the Missouri Department of Transportation (MoDOT), said the department considered asphalt recycling and reclamation as an alternative for road repairs.

“There are cost benefits of recycling,” he said. “We can treat a deeper section of roadway at the same cost of placing a thinner section of new material.”

MoDOT’s first asphalt reclamation project, a 7-mile stretch of Route 71 south of Maryville, Mo., saved the department more than $500,000.

“We see more recycling being done as we look at options to do more with less and come up with longer term solutions at the same cost,” Schroer said.