Reconstructing Composite Pavements – Rubblization and HMA

Presentation

Recent Developments in Concrete Rubblization and Asphalt Overlay for Airfield Pavements

Presentation

Antigo Construction Family of Companies Airfield Rubblization Projects

List of projects

Antigo Construction Family of Companies Completed Square Meters by Type

Summary table

Interstate Highway Rubblization Projects by State, 1996-2024

List of projects

Highway Rubblization Projects with Concrete Overlays by State, 1999-2024

List of projects

Crack & Seat Concrete Pavement with Asphalt Overlay Projects – Southeast Wisconsin Local Roads, 1983-2024

List of projects

Crack & Seat Concrete Pavement with Asphalt Overlay Projects – Iowa 2-Lane Highways, 1986-2024

List of projects

California Interstate Crack & Seat Concrete Pavement with Asphalt Overlay Projects, 1991-2024

List of projects

Antigo’s MHB Urban Removal Breaking Projects, 1996-2024

List of projects

Antigo’s Industrial Sites Removal Breaking Projects, 1985-2024

List of projects

Antigo’s Airports Removal Breaking Projects, 1982-2024

List of projects

Antigo Construction Family of Companies Completed Square Yards by Type

Summary table

Antigo’s International Projects, 1999-2024

List of projects

Guidelines for Use of Asphalt Overlays to Rehabilitate PCC Pavements, NAPA IS-117

The National Asphalt Pavement Association (NAPA) updated this publication which was first published in 1994. It now provides up-to-date information on of the use of fractured slab techniques to rehabilitate PCC pavements with asphalt overlays.

Asphalt Pavement Alliance 2022 Perpetual Pavement Awards

Antigo Construction performed concrete pavement rubblization on the Illinois DOT’s I-74 project that was recognized as a Perpetual Pavement Award project for 2022.

Caltrans Plans for Perpetual Pavements

California Department of Transportation project on I-5 in Sacramento County utilized concrete pavement crack & seat and asphalt overlay to build a perpetual pavement.

Rubblization or Crack and Seat – Things to Consider

Things to consider when evaluating a potential fractured slab and asphalt overlay project with an emphasis on choosing between the range of fractured slab techniques.

Perpetual Pavement Practices Convert Concrete Interstates in Illinois

Illinois DOT project on I-70 in Clark County that won a Perpetual Pavement Award in the By Conversion category utilized concrete pavement rubblization and asphalt overlay.

Perpetual Pavement: Award-Winning Design

Piatt County (IL) won a prestigious Perpetual Pavement Award (PPA) — only the second U.S. local public agency road project to ever receive such recognition. The project was the first rubblization and asphalt overlay of a whitetopping pavement.

Asphalt Pavement Alliance 2021 Perpetual Pavement Awards

Antigo Construction performed rubblization or crack & seat on 5 of the Perpetual Pavement Award projects for 2021.

Caltrans Plans for Perpetual Pavement

This very successful crack & seat and asphalt overlay project received an Asphalt Pavement Alliance 2021 Perpetual Pavement by Design Award.

Tennessee DOT Uses Innovation to Rebuild Nashville’s I-440

This very successful Design-Build project converted a deteriorated concrete pavement into a new asphalt pavement utilizing concrete rubblization.

Rubblization Practices Evaluated in Illinois

A recently released report out of the University of Illinois Center for Transportation entitled “Performance of Interstate Rubblization in Illinois” summarizes the performance of rubblized pavements on the Illinois interstate system over the last two decades.

Guide to Concrete Overlays

This guide presents basic principles needed by pavement engineers for the design and construction of concrete overlays on existing asphalt, composite, and concrete pavements. See pages 105 and 107 for information on rubblization of concrete pavement prior to a concrete overlay.

Breaking Upper Layer of Concrete while not Damaging Lower Layer

Pictorial examples of Antigo’s process of breaking an upper Layer of concrete while not damaging a lower layer.

Crack & Seat Airport Pavements – Project Examples

Pictorial examples of Antigo’s process of cracking & seating airport pavements prior to asphalt overlay.

Antigo International – Concrete Pavement Rehabilitation

In-situ recycling options for concrete pavement rehabilitation provided worldwide by Antigo International.

Rubblization and Asphalt Overlay of a 2-Lane Highway Constructed under Traffic

Pictorial description of Antigo’s process of rubblizing a 2-lane concrete highway prior to asphalt overlay constructed under traffic.

Nighttime Rubblization and Asphalt Overlay

Pictorial description of Antigo’s process of rubblizing concrete highways prior to asphalt overlay during nighttime lane closures.

Breaking and Removing Continuously Reinforced Concrete Pavement (CRCP)

Pictorial description of Antigo’s process of breaking CRCP for removal.

Break Concrete for Removal Around the World

Examples of the breadth of locations where Antigo has completed projects.

Modified Rubblization Specification

Construction specification prepared by Antigo Construction.

Types of Fractured Slab Techniques with MHB

Antigo uses the following descriptions to describe the range of fractured slab techniques performed with the MHB Badger Breaker® (MHB).

Performance of Interstate Rubblization in Illinois, FHWA-ICT-21-005

This Illinois Center for Transportation (ICT) report summarizes the performance of several interstate rubblizing projects in Illinois by analyzing available data in Illinois Department of Transportation’s pavement management system. The report finds that, overall, rubblization is providing good to excellent performance and exceeding design expectations.

Cracking & Seating Concrete Pavement at Airports, 1984 to 2020

List of projects

Breaking & Seating Concrete Pavement with MHB Badger Breaker® in Ohio, 2000 to 2020

List of projects

Breaking & Seating Concrete Pavement in Kentucky, 1995 to 2020

List of projects

Benefits of Rehabilitating Concrete Pavements with Slab Fracturing and Asphalt Overlays, NCAT Report 20-03

This National Center for Asphalt Technology (NCAT) study comprehensively synthesized historical experiences with crack and seat (C&S), break and seat (B&S), and rubblization methods for the rehabilitation of PCC pavements with asphalt overlays.

Rubblization Gives New Life to Dying Roads Nationwide

Departments of Transportation across the country are seeing that rubblization is a key tactic for bringing new life to aging concrete pavements.

Rubblize to Rehabilitate – West Virginia

Through the monitoring of pavement conditions in West Virginia, the DOH has documented that the warranty pavements, using rubblization, are out-performing traditional full depth new construction pavements.

Evaluation of the Terminal Boulevard (SR 406) Concrete Rubblization Project

The purpose of this study was to document the current condition of the rubblized and reconstructed pavement on Terminal Boulevard (SR 406) in Norfolk, VA, and to generate baseline pavement performance information.

WisDOT Facilities Development Manual Chapter 14.25.15 Concrete Pavement Rubblization

The purpose of this procedure is to provide guidance on rubblization of concrete pavement.

WisDOT Specification 335 Rubblized Pavement

Wisconsin DOT concrete rubblization specification.

I-70 Extended Life Pavement Performance

Charles Wienrank, P.E., Pavement Design Engineer, Illinois DOT, presentation at 2019 IAPA Annual Meeting.

Non-Destructive Modulus Testing and Performance Evaluation for Asphalt Pavement Reflective Cracking Mitigation Treatments

Four treatments were evaluated to determine their effectiveness in mitigating reflective cracking via non-destructive FWD tests and Surface Wave Method tests to measure layer modulus, along with field pavement performance surveys.

Mechanistic Design Data from ODOT Instrumented Pavement Sites – Phase II Report

This investigation examined data obtained from three previously-instrumented pavement test sites in Oregon. Data processing algorithms and templates were developed for each test site that facilitated full processing of all the data to build databases representing each site. Investigation of site data found that most of the collected data could be successfully processed and observed trends in the data were as expected (e.g., seasonal changes affected pavement response). The location that compared rubblized base to aggregate base clearly demonstrated the effect of the rubblized base through a 50% reduction in strain at the bottom of the asphalt layer. Further investigations of the data may be warranted and user's guides provided in this report will enable those investigations to proceed by ODOT staff.

Mechanistic Design Data from ODOT Instrumented Pavement Sites – Phase 1 Report

This investigation examined data obtained from three previously-instrumented pavement test sites in Oregon. Data processing algorithms and templates were developed for each test site that facilitated full processing of all the data to build databases representing each site. Investigation of site data found that most of the collected data could be successfully processed and observed trends in the data were as expected (e.g., seasonal changes affected pavement response). The location that compared rubblized base to aggregate base clearly demonstrated the effect of the rubblized base through a 50% reduction in strain at the bottom of the asphalt layer.

The right CSOL-ution

Washington State DOT’s last-ditch play against aging pavements is a unique success.

Route 65: The Rebuild, Springfield, MO

Millstone Webber and MoDOT presentation on fast track reconstruction project.

Monticello Road Whitetopping Rubblization

Presentation by Eric Seibring, Piatt County Engineer, on the first rubblization and asphalt overlay of a whitetopping pavement.

Reconstructed Runway Rises from Rubble at Coles County Memorial

The project team at Coles County Memorial Airport in Illinois chose rubblization and asphalt overlay to reconstruct the runway to keep costs down and to minimize disruption to the day-to-day operations of the airport.

Repair of the Surface of Concrete by Crushing Hammer (Rubblizing)

Article on rubblization in Poland from the technical journal DROGOWNICTWO (Highway Engineering).

- Content in Polish language.

Validation of Staged Construction Pavement Design with the Falling Weight Deflectometer

This paper documents the Illinois Tollway staff's monitoring and observation process of the I-88 rubblization and asphalt overlay project during the first 9 years of service to validate the original design assumptions and verify the Stage 2 pavement design strategy and overall pavement performance.

Towards Sustainable Pavement Systems: A Reference Document

This reference document has been prepared to provide guidance to the pavement community on sustainability considerations in pavement systems, drawing from and synthesizing the large and diverse body of knowledge that exists on pavement sustainability. Crack & seat and rubblization are identified as sustainable construction techniques.

Improved design of overlay treatments to concrete pavements

The objective of this UK research was to develop improved design guidance for asphalt overlays to concrete pavements by providing techniques that will reduce the thickness of overlay while still minimizing the occurrence of reflective cracking. The crack & seat and rubblization are techniques are addressed.

The use of crack and seat treatment in refurbishment of airfield pavements

The overall purpose of the guide is to provide enough information to enable those engineers not familiar with crack and seat technology to be able to conduct effective maintenance of concrete pavements at airfields.

Simplified Crack, Seat, and Overlay Design for Scottish Roads

Investigation of a simplified design approach for asphalt overlays on cracked and seated or rubblized cement bound material (CBM) in Scotland.

Rapid Pavement Rehabilitation with Long Life Asphalt Concrete

Project experience from the rehabilitation of Interstate 710 in Long Beach, California using 55-hour weekend closure and crack & seat with asphalt overlay.

Coles County Memorial Airport, Mattoon, Illinois, Rubblization of Runway 11-29

Hanson Engineering and Howell Paving presentation on rubblization and asphalt overlay of an airport runway.

Norwalk Uses Crack & Seat to Rehabilitate Roadways

Description of how a city and its engineering firm are using crack & seat and asphalt overlay to rehabilitate failing concrete pavements.

Thoroughbreds, Thorough Work — Crews Execute Extensive Asphalt-paving Work on Hwy. 60 in Kentucky

Description of a break & seat and asphalt overlay project that included alternative pavement bid process.

Wisconsin Crack & Seat Specification

Specification

South Dakota Crack & Seat Specification

Specification

Performance of Techniques to Minimize Reflection Cracking and Associated Developments in Pavement Investigation for Maintenance of UK Military Airfield

Crack & seat technique performed well in UK airfield trials.

Modified Rubblization – Ohio Asphalt Magazine Winter 2015

Article describing use of modified rubblization and asphalt overlay on city streets in Greenfield, Wisconsin.

Discussion of “Modified Rubblization”

Presentation

Rubblizing in an Urban Environment

Presentation

The Cross Road – Blessed Route the Beneficiary of FDR Process

A full-depth reclamation (FDR) project involving the removal of a failed portland cement concrete pavement and the construction of an 8-in. stabilized reclaimed asphalt pavement (RAP) and aggregate base.

Cracking & Seating Airport Pavements in the UK

Overview of the process prepared by Antigo Construction.

IS-132 Rubblization

For an excellent introduction to rubblization of concrete pavement and asphalt overlay, we suggest the National Asphalt Pavement Association's publication IS-132 Rubblization.

WisDOT Construction & Materials Manual Chapter 3.50 Rubblizing Concrete Pavement

Wisconsin DOT engineer guidance regarding the rubblization of concrete pavement.

Nebraska DOR Cracking and Seating Concrete Pavement

Specification

Montana DOT PCCP Pavement Cracking and Seating

Specification

Iowa Crack & Seat Specification

Specification

Idaho DOT Crack & Seat Concrete Pavement

Specification

Survival Analysis for Composite Pavement Performance in Iowa

This study investigates the performance of composite pavements composed of a flexible layer over a rigid base. Four composite pavement rehabilitation methods are involved in the research: mill and fill, structural overlay, rubblization and heater scarification.

Using Recycled Concrete in MDOT’s Transportation Infrastructure

Crushed concrete aggregate (CCA) is granular material manufactured by removing, crushing, and processing old concrete for reuse as an aggregate source in new construction.

Transportation Applications Of Recycled Concrete Aggregates

The purpose of this review was to capture the most advanced uses of recycled concrete aggregate (RCA) for transportation uses in the United States. This knowledge would then be transferred to all State Transportation Agencies (STA).

Recycling Concrete Pavements

This engineering bulletin provides background information on recycling concrete pavements into recycled concrete aggregate (RCA) for use in bases, subbases, new concrete mixtures, granular fill, etc.

Rubblization of Continuously Reinforced Concrete Pavement

Pictorial presentation of the process.

Rubblization and HMA Overlay in Faribault County

County State Aid Highway (CSAH) 16, east of Blue Earth, MN, was rubblized and overlaid in 2004.

Rubblization – A Way to Save Time, Money, and Resources

When concrete pavements reach a certain level of deterioration, rubblization of the concrete with an asphalt overlay is the easiest, cheapest, and most effective way to rehabilitate the pave­ment in the shortest amount of time.

Breaking and Seating of Rigid Pavements

Breaking and seating has been utilized extensively in Kentucky to rehabilitate portland cement concrete pavements. Experience over three or four years with this type of design and construction are summarized and reported.

Breaking and Seating of Concrete Pavements: Kentucky’s Experience

This survey includes a detailed visual survey and falling weight deflectometer testing to determine the in situ condition of the pavement structure.

Inbound and Outbound Pena Boulevard Reconstruction

Denver International Airport (DIA) presentation on rubblization and concrete overlay.

Less Time, More Bonus Money

Reconstruction of I-465 near Indianapolis, Indiana.

A Base Stacked for Strength

Reconstruction of a taxiway at Des Moines International Airport.

Kentucky’s experience with rehabilitating PCC pavements with asphalt overlays

Article on break & seat and asphalt overlay in Kentucky.

New Runway Ready for Take-Off

Rebuilding a critical runway at Fairchild Air Force Base required attention to every last detail - from the concrete to the construction technique to the calendar.

Evaluation of Rubblized Pavement Sections in Michigan Constructed between 1988 and 2002

This report has been prepared to summarize the relevant findings regarding the performance of the pavement sections rubblized using the MHB between 1997 and 2002 in Michigan and the performance of pavement sections rubblized using the RFB between 1988 and 2000.

Evaluation of Concrete Slab Fracturing Techniques in Mitigating Reflective Cracking Through Asphalt Overlays

This report presents the results of an evaluation of concrete slab fracturing techniques as a means of arresting or retarding reflective cracking through asphalt overlays placed on severely distressed portland cement concrete pavement.

Breaking / Cracking and Seating Concrete Pavements

National Cooperative Highway Research Program Synthesis of Highway Practice 144 by Marshall R. Thompson.

Discussion of “Full Rubblization” & “Modified Rubblization”

Presentation

Rubblization: Making an Impact in Michigan

Since 1988, the Michigan Department of Transportation has been using rubblization as a road rehabilitation method.

Antigo Construction, Inc. in Afghanistan

The following is the first in a series of articles and photos regarding Antigo Construction's involvement with a USAID project in Afghanistan to rebuild the Kandahar to Herat Highway.

FAA Engineering Brief No. 66, Rubblized Portland Cement Concrete Base Course

Engineering Brief No. 66 provides guidance and specifications for rubblization of existing Portland cement concrete pavements.

HWD Testing of Rubblized Sections of Taxiway W1 at Detroit Metro Airport

Report on Heavy Weight Deflectometer testing of the rubblized sections of Taxiway W1.

Rubblized Concrete: Good Support for Concrete Overlays

This research sought to verify that PCC over rubblized concrete pavement is a strong, durable option for overlays of aging concrete roadways.

Performance Contracting for Construction on the M-115 in Clare County, MI

This report documents the Michigan Department of Transportation's (MDOT) HfL demonstration project, which involved performance contracting for construction (PCfC) on M-115, a two-lane rural highway in Clare County, MI.

Development of Guidelines for Rubblization Final Report

This report presents the results of Airfield Asphalt Pavement Technology Program Project (AAPTP) 04-01, Development of Guidelines for Rubblization. The objective was to document the state of the art in rubblization technology for airfield pavements.

Crack and Seat PCC Pavement Prior to Resurfacing US 59 – Shelby County

1993 Iowa DOT technical report.

Rubblization of Existing Airfield Pavements at King Abdulaziz International Airport, Jeddah Saudi Arabia

Presentation

On Track Newsletter, Winter 2004 / 2005, R.A. Smith & Associates, Inc.

Rubblizing may sound like just another funny word-but communities and county highway departments will like the sound of how rubblizing can provide significant time and cost savings.

From Rubble to Runway

The arrival of a lone KC-135 at Grand Forks AFB, N.D. on Oct. 30, 2005 marked the unofficial opening of Air Mobility Command's newest state-of-the art runway and the end of a long summer of construction at the base.

Performance of Colorado’s First Rubblization Project on I 76 Near Sterling

This report documents the six-year performance of the Colorado DOT's first rubblization of PCCP project.

Hot-Mix Asphalt Overlay Design Concepts for Rubblized Portland Cement Concrete Pavements

Transportation Research Record 1684, paper by Marshall R. Thompson.

Structural Characterization of Iowa’s Rubblized PCC Pavements

This paper describes a field study undertaken to investigate the performance of rubblized pavements in Iowa, which includes characterization of the rubblized Portland cement concrete (PCC) layer (layer coefficient and modulus) using a neural networks-based layer moduli backcalculation program. The average rubblized PCC layer coefficient and backcalculated modulus of the rubblized layer in Iowa were found to be 0.19 and 539 MPa (78 ksi), respectively.

Life Cycle Assessment – I-5 Seattle

This paper compares three different replacement options for an aging portland cement concrete (PCC) pavement using LCA process-based protocol. Those options are: remove and replace with PCC pavement, remove and replace with hot mix asphalt (HMA) pavement, and crack-and-seat the existing pavement followed by a HMA overlay.

Layer Coefficient Values for Cracked and Seated Concrete

The WisDOT Bureau of Technical Services is interested in identifying layer coefficient values used by state DOTs nationwide for cracked and seated concrete, in comparison with values used for rubblized concrete.

Improved Design of Overlay Treatments

The objective of this research was to develop improved design guidance for asphalt overlays to concrete pavements by providing techniques that will reduce the thickness of overlay while still minimizing the occurrence of reflective cracking.

Rubblization Using Multi-Head Breaker Equipment

This paper by Professor Marshall Thompson documents the development, capabilities, and effective utilization of the MHB for rubblizing concrete pavement.

Reflection cracking on airfield pavements – a design guide for assessment, treatment selection and future minimization

This guide has been prepared for Defence Estates (UK) to provide guidance on the identification, categorization and treatment of reflection cracking in airfield pavement structures.

Practical Method of Ensuring the Success of Crack and Seat Operations Using FWD

This procedure has two phases: (a) determine the hammer parameters (height and spacing) that develop good cracking patterns, full depth cracks with adequate aggregate interlock between the cracked segments and (b) determine the optimum number of passes of a rubber-tired roller.

Field Performance of Crack and Seat Projects

This paper presents the results of an analysis of seventy crack and seat projects from twelve states throughout the United States.

Performance of Asphalt Overlays on Cracked & Seated Pavement

Presentation by David Strand, Wisconsin State Design Engineer for Highways, made in 1985 reporting on Wisconsin DOT’s first six years of experience with crack & seat.