Construction Updates - MnROAD

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2022 Construction

MnROAD will be constructing 45 mainline cells test sections related to through NRRA along with a partnership with Midstate Reclamation to develop a cold-in-place study with 4 test sections on the LVR.

NRRA HMA and PCC on Mainline
Neo-Pave Cold-in-Place Recycling on Low Volume Road

Weekly Updates

Week of August 29th

C.S. McCrossan placed 1st lift of HMA in driving lane shoulder of cells 2201-2202 and 2207-2208
C.S. McCrossan continued granular and RAP shouldering activities and general site clean up
C.S. McCrossan sampled HMA cores
MnROAD and District 3 performed surface testing of concrete test cells 2209-2227

Week of August 22nd

C.S. McCrossan continued granular and RAP shouldering activities and general site clean up
C.S. McCrossan placed HMA in lanes of cells 2201-2202 and 2207-2208
C.S. McCrossan performed final grading of shoulder aggregate in test cells 2201 - 2208
MnROAD and District 3 performed surface testing of concrete test cells 2209-2227

Week of August 15th

C.S. McCrossan placed 5Q aggregate unbound base in driving lane shoulder of test cell 2209
C.S. McCrossan performed final grading of shoulder aggregate in test cells 2209 - 2224
C.S. McCrossan placed HMA in shoulders of test cells 2209 - 2224
PCi placed concrete in full depth repair panels in Cells 613, 160-162, and 505-805
MnROAD performed dynamic friction trailer testing in test cells 2209-2227
MidState performed Cold-Inplace-Recycling of test cells 2201-2202 and 2207-2208

Week of August 8th

PCi paved Cells 2217, 2218 and 2209 for the cement alternative study
PCi prepped full depth repair panels in Cells 613, 160-162, and 505-805
C.S. McCrossan placed aggregate in driving lane shoulders of 2227-2217
C.S. McCrossan placed 3rd lift of HMA in perpetual pavement Cells 2228 and 2229
C.S. McCrossan placed 3rd lift of HMA in reflective cracking Cell 2230
MnROAD and District 3 support continued to place concrete sensor
Fresh concrete mixes were sampled and tested by AET and Braun
FHWA trailer provided additional testing services for concrete mixes
FHWA trailer left at the end of the week for another project but will return for additional break tests
First full rain delay on 8/12, C.S. McCrossan dewatered shoulders

Week of August 1st

PCi paved Cells 2215, 2216 and 2219-2224 for the cement alternative study
PCi paved Cell 2225 with concrete for the weigh in motion study
PCi paved Cells 2226 and 2227 with concrete for early loading in white topping cells
C.S. McCrossan continued granular and RAP shouldering activities and general site clean up
MnROAD and District 3 support continued to place concrete sensor
Fresh concrete mixes were sampled and tested by AET and Braun
FHWA trailer provided additional testing services for concrete mixes

Week of July 25th

C.S. McCrossan placed RAP to stabilize and re-grade shoulders of HMA Cells 2231-2239
C.S. McCrossan installed conduit from driving shoulder to passing shoulder for future Weigh in Motion
PCi trimmed the base of Cells 2209-2216, 2217-2224 and 2225
PCi set up paver, drag for texture, and sprayer for curing compound
PCi paved concrete cells 2210, 2211, 2212, 2213 and 2214 for the cement alternatives study
Cell 2209 was partially paved, but was removed due to mix related issues with the paver and the plant
Agg Industries unloaded supersacks of cementitious material into tanker trucks
First partial rain delay of this construction project on 7/26
MnROAD and District 3 support installed sensors
MnROAD held an open house with concrete paving demonstration
Fresh concrete mixes were sampled and tested by AET and Braun
FHWA trailer provided additional testing services for concrete mixes>

Week of July 18th

VRAM installed in Cells 2228-2239
C.S. McCrossan placed final lift of HMA in Cells 2231-2239
C.S. McCrossan placed 2nd lift of shoulder in Cells 2228 and 2229
PCi delivered and set up concrete paver
Federal Highway Administration concrete test lab trailer arrives

Week of July 11th

C.S. McCrossan placed HMA non-wear 2nd lift in Cells 2228 and 2229
C.S. McCrossan made cuts in HMA Cells 2230-2239 for reflective cracking study
C.S. McCrossan milled HMA surface in Cells 2230-2239 and 2226-2227
C.S. McCrossan removed concrete in Cells 914-514
C.S. McCrossan finished placing sub-base and base in Cells 2216-2209
MnROAD installing sensor conduit in Cells 2209-2216

Week of July 4th

Happy Independence Day!
MnROAD installed sensor conduit in subgrade of Cells 2217-2224
C.S. McCrossan placed HMA non-wear lift in Cells 2228 and 2229
C.S. McCrossan finished concrete and continued aggregate removals in Cells 2216-2209
MnROAD marked HMA cuts in Cells 2230-2239 for reflective cracking study
C.S. McCrossan fine graded Cells 2217-2224
C.S. McCrossan finished excavation in Cell 2225 and placed aggregate sub-base and base.

Looking ahead to week of July 11th:

C.S. McCrossan to place HMA non-wear 2nd lift in Cells 2228 and 2229
C.S. McCrossan to make HMA cuts in Cells 2230-2239 for reflective cracking study
C.S. McCrossan to finish placing sub-base and base in Cells 2216-2209
C.S. McCrossan to remove concrete in Cells 914-514
C.S. McCrossan to mill HMA surface in Cells 2230-2239 and 2226-2227
MnROAD to install sensor conduit in subgrade of Cells 2216-2209
MnROAD to run sensor wire through conduit in Cells 2217-2224
MnROAD to continue material sampling and testing

Week of June 27th

C.S. McCrossan finished placing Sub-base and Base Aggregate in Cells 2228 and 2229
C.S. McCrossan paved second lift of HMA base course in cells 2230-2239
C.S. McCrossan continued excavations of Cells 2224-2209
C.S. McCrossan placed Sub-base and Base in Cells 2224-2217
C.S. McCrossan daylighted existing drain tile from Cell 613
MnROAD installed sensor conduit in Subgrade of Cells 2223-2220 and Base of Cell 2229
MnROAD placed Base and HMA sensor arrays in Cell 2228
MnROAD and Michigan State University placed geotechnical sensors in Cells 2228 and 2229
MnROAD, University of Texas El Paso, and Michigan State performed geotechnical testing of subbase and base in Cell 2229

Looking ahead to week of July 4th:

MnROAD to install sensor conduit in Subgrade of Cells 2221-2217
MnROAD to continue concrete sensor prep
C.S. McCrossan to continue concrete and aggregate removals in Cells 2216-2209
C.S. McCrossan to place Sub-base and Base in Cells 2216-2209
C.S. McCrossan to fine grade Cells 2217-2224
C.S. McCrossan to place HMA non-wear lifts in Cells 2228 and 2229
MnROAD to mark future HMA cuts in Cells 2230-2239 for reflective cracking study
MnROAD to continue material sampling and testing

Week of June 20th

C.S. McCrossan finished grading and rolling Cells 2230-2239
MnROAD installed environmental and dynamic sensors in Cells 2230-2239
University of North Dakota installed sensors in Cell 2232
MnROAD performed FWD, LWD, and DCP testing on Agg. Base in Cells 2230-2239
C.S. McCrossan paved first lift of base course in cells 2230-2239
C.S. McCrossan continued removal of concrete Cells 2209 – 2217
C.S. McCrossan began excavations of Cells 2224 – 2218
MnROAD installed conduit for sensors in Cell 2224 and 2229
C.S. McCrossan placed sub-base in Cell 2224
University of Texas El Paso (UTEP), Michigan State (M.S.), and MnROAD installed sensors in subgrade of Cells 2228 and 2229
UTEP/MnROAD performed intelligent compaction testing in Cell 2229
M.S./MnROAD performed DCP, LWD, and density tests on subgrade and sub-base in Cells 2228-2229
SolMax representatives were on site to install geofabric in Cell 2229
C.S. McCrossan made additional excavations and place coarse filter aggregate in Cell 2229
Evercore extracted cores from first lift of Cells 2230-2239
After labor shortage due to Covid protocols, John Bormann from Maplewood recertified and rescheduled to provide nuclear density tests for HMA in Cells 2230-2239 and subbase in 2228-2229

Looking ahead to week of June 27th:

C.S. McCrossan to finish placing Sub-base and Base in Cells 2228 and 2229
UTEP, M.S. and MnROAD to install sensors in Sub-base and Base in Cells 2228-2229 and continue testing
C.S. McCrossan to pave second lift of base course in cells 2230-2239
C.S. McCrossan to continue excavations of Cells 2224-2209
C.S. McCrossan to place Sub-base and Base in Cells 2224-2209
MnROAD to install sensor conduit in Subgrade of Cells 2223-2209 and Base of Cell 2229
MnROAD to begin marking of cuts in Cells 2230-2239 for reflective cracking study

Week of June 13th

C.S. McCrossan finished grading and rolling Cells 2230-2239
C.S. McCrossan began removal of concrete Cells 2216-2227 and stockpiling of aggregate import
C.S. McCrossan excavated to subgrade in Cells 2228 and 2229
INGIOS performed Intelligent Compaction (IC), Automated Plate Load Tests (APLT), and Dynamic Cone Penetrometer (DCP) tests on Cells 2201-2202, 2207-2208, and 2230-2239
MnROAD to perform FWD, LWD, and DCP testing on Agg. Base in Cells 2230-2239
MnROAD and Maplewood Office continued installing sensors in Aggregate Base
MnROAD and D3 continued to prep sensors for concrete cells

Looking ahead to week of June 20th:

MnROAD to continue to prep sensors for concrete cells
C.S. McCrossan to continue removal of concrete Cells 2209 - 2217
C.S. McCrossan to begin excavations of Cells 2224 – 2209
University of Texas El Paso (UTEP) to install sensors in subgrade and sub-base of Cells 2228 and 2229
C.S. McCrossan to place sub-base in cells 2228 and 2229
UTEP to perform intelligent compaction testing in Cells 2228 and 2229
University of North Dakota to install sensors in Cell 2232
MnROAD to perform FWD, LWD, and DCP testing on Agg. Base in Cells 2230-2239
MnROAD to install environmental and dynamic sensors in Cells 2230-2239
C.S. McCrossan pave base course in cells 2230-2239

Week of June 6th

C.S.McCrossan laid test strips for SPWEB 540B and SPWEB 540C mixes at their facility in Maplewood
ANTIGO crushed concrete pavement for removal
Northwestern Surveying & Engineering staked Cells 2230-2239
C.S. McCrossan began grading Cells 2230-2239
District 3 and MnROAD mowed the ditch and continued sensor prep work and forensic testing
MnROAD and Maplewood Office began installing sensors in Aggregate Base

Looking ahead to week of June 13th:

C.S. McCrossan to finish fine grading of Cells 2230-2239
C.S. McCrossan to begin removal of concrete Cells 2209-2227 and stockpiling of aggregate import
C.S. McCrossan to begin excavations of Cells 2209-2227
INGIOS to perform Intelligent Compaction (IC) and Automated Plate Load Test (APLT) on Cells 2201-2202, 2207-2208, and 2230-2239
MnROAD to continue to install sensor in Cells 2230-2239
MnROAD to continue to prep sensors for concrete cells

Week of May 30th

Memorial Day Holiday
Caterpillar Global Paving (CAT) performed 3 days of asphalt milling.
District 3 provided personnel and equipment for hauling, stockpiling, and pavement surface cleaning.
MnROAD provided assistance to UNH with forensic work including coring and FWD testing.
District 3 and MnROAD staff continued sensor preparation work and forensic testing.

Week of May 23rd

Caterpillar Global Paving (CAT) performed 5 days of asphalt milling.
This work is a partnership between MnROAD, CAT, and the University of New Hampshire (UNH).
CAT utilized 3 mills with different milling parameters for CAT to test their equipment and for UNH to study the effects of milling on the underlying pavement.
District 3 provided personnel and equipment for hauling, stockpiling, and pavement surface cleaning.
MnROAD provided assistance to UNH with forensic work including coring and FWD testing.
District 3 and MnROAD staff continued sensor preparation work and forensic testing.

Week of May 16th

Bio-logs were delivered and installed by J.R. Larson as part of the Erosion Prevention and Sediment Control plan.
District 3 and 7A provided support for pavement coring needed for forensic and design work.
For this project over 800 Asphalt Cores and approximately 200 Concrete Cores were removed from the test sections prior to construction.
MnROAD staff with District 3 support installed conduit, vaults, and tower bases in preparation for the almost 900 sensors to be installed during construction.
MnROAD researchers conducted forensic testing.
MnROAD conducted bus tours of Mainline as part of the 2022 NRRA MnROAD Open House.

2021 Construction

MnROAD developed test sections to support two studies from NRRA and Minnesota Local Road Research Board at MnROAD and 15th Street located in the City of St. Michael to study spray rejuvenator products.

2021 Construction Report (in development)

2020 Construction

NRRA develop a research project and test sections near Emily Minnesota that are being utilized to develop a better understanding of HMA rejuvenators and their long-term effects on performance.

2020 Construction Report (in development)

2017 Construction

NRRA Phase 3 Construction

NRRA Phase-3 Construction of many test sections on MnROAD mainline and LVR with both HMA and PCC surface layers.

2016 Construction

MnROAD partnered with NCAT to reconstruct 8 mainline HMA test sections. These test sections support a national pooled fund study on cracking group experiment focusing on low temperature cracking.

2016 Construction Report (in development)

2013 Construction

This season's construction focused on Reconstruction and Repair of Mainline Cells 160-163 and 613 along with LVR cells 32 and 140-240.

2011 Construction

MnROAD 2011 Reconstruction and Repair of PCC Mainline Cells 5, 6, 63, & 96

Four test cells on the MnROAD Mainline were in need of reconstruction or substantial repairs in 2011. This opportunity allowed us to enhance the research program at MnROAD by evaluating and demonstrating the following materials and methods:

the performance of three gradations to optimize paste content, workability, and durability;
longitudinal tining as a quiet surface;
the use of drainable, stable aggregate bases to enhance pavement life; and
roller compacted concrete on the shoulders.

Also, a thin (5") unbonded concrete overlay using a non- woven geotextile interlayer was constructed on half a cell, and, repairs were made on a thin whitetopping cell to evaluate best practices to maintain concrete overlays.

Stabilized Full Depth Reclamation on Cell 28

With budgets being stretched and local sources of pavement materials being depleted, reconstruction of low volume roadways is becoming difficult for local agencies to fund. Cheaper methods, such as the use of gravel material, have been adopted to try and alleviate these costs.

The construction on Cell 28 explored alternative methods of paving that are both renewable and relatively inexpensive in overall costs. The plan attempted to utilize in situ materials of the previous Cell 28 construction to repave the cell in a sustainable manner using 100% of the existing materials. The cell consisted of 100% recycled pavement that has no transportation costs, material costs, and relatively inexpensive operating costs providing for a better quality road. This cell has the potential to serve as a model for maintaining thousands of low volume road miles.

2010 Construction Updates

Three new test cells were constructed on the Mainline to investigate the design, construction, and performance aspects of composite pavements. Construction began in mid-April and was completed by the end of May.

2008 Construction Updates

Reconstruction began in April 2008 and was completed in November. Over 20 test cells were either reconstructed or rehabilitated with asphalt or concrete surfacing. MnROAD staff installed over 1400 sensors in the various pavement layers during construction.

2007 Construction Updates

MnROAD reconstruction on the Low Volume Road in 2007 included fly ash stabilized full depth reclamation, polyphosphoric acid modified asphalt, and two new cells to evaluate the impact of implements of husbandry vehicles on low volume roadways.

2007 Low Volume Road and Farm Loop Construction Report (pdf)

Two Cells on the mainline were diamond ground with an innovative grind for quiet pavements

Report of Diamond Grinding on Cells 7 and 8 (pdf)

2006 Construction Updates

In 2006 Cell 1, 27, and 28 were reconstructed by MnROAD. There were three significant aspects of research behind the test cell reconstruction: field validation of Geocomposite Capillary Barrier Drain (GCBD) for limiting moisture changes in pavements, Intelligent Compaction (IC) research performed on the unbound base and subgrade layers, and accelerated testing of PG 52-34 binder to support a Local Road Research Board (LRRB) project. These reports document the previous pavement condition, pavement structural and mixture designs, instrumentation plan, field construction activities, material sampling, and laboratory test results.

Pervious concrete helps to divert polluted and excess water from local water sources. In 2006 MnROAD and its partners collaborated on a pervious concrete sidewalk project to help study how to effectively use pervious concrete to best limit negative environmental factors.

Pervious Concrete Sidewalk Project

2005 Construction Updates

In 2005, MnROAD continued to study the effectiveness of pervious concrete in its test cells. MnROAD was researching the pervious concrete's inherent sustainability during the varying environmental factors that come with each season especially safety during the winter seasons.

2005 Pervious Concrete Driveway Project

2004 Construction Updates

2004 marked several different construction and research projects for MnROAD. Cells 60- 63 were constructed using whitetopping technique to replace earlier whitetopping cells constructed in 1997. The report below contains the relevant information about the reconstruction and the data attained through the seven years research.

Construction Report for MnROAD Thin Whitetopping Test Cells 60-63

Mesabi Hard Rock aggregate began to be tested during 2004 resulting in several reports and studies. The purpose of the research was to see the utilization possibility of a new and Minnesota based resource.

Cell 26 was reconstructed to replace a test cell that had failed prematurely.

2004 Cell 26 Reconstruction

1999 Construction Updates

This paper's purpose is to provide an update on the pavement condition of MnROAD's three low volume road (LVR) SuperPave test cells constructed in 1999 with different asphalt binders. These cells were built to field validate the current low temperature performance grading (PG) system currently being used at MnDOT and many other agencies around the world.

1999 SuperPave Tracking

1996 Construction Updates

This report focuses on the second construction phase of the Minnesota Road Research facility (MnROAD) and evaluates three typical, locally available, surfacing aggregates along with a rollover section from the initial phase for performance.

Evaluation of Aggregate Sections at MnROAD

1990-1993 Construction Updates

These are initial reports released by MnROAD during its original construction.