2012 Sheldon G. Hayes Award

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The Sheldon G. Hayes Award winner is determined through a two-year process. Highway pavement projects using more than 50,000 tons of asphalt are eligible for consideration. Initially, they must win a Quality in Construction (QIC) Award, which is determined by numerical scores given by pavement engineers at the National Center for Asphalt Technology (NCAT) on the basis of how well the contractor met the specifications and achieved density on the finished pavement.  All the pavements that meet a benchmark figure are given the QIC award.

 

The year after a project wins a QIC Award, it may be considered for the Sheldon G. Hayes Award. The top-ranked projects from each year are tested for smoothness, then visually inspected by an independent pavement consultant with many years of experience in the industry. This year, the evaluators praised the contestants for high-quality construction practices resulting in smooth, safe, and durable pavements.

 

Read more about the 2012 Sheldon G. Hayes projects in the May/June 2013 edition of Asphalt Pavement magazine.

 

 

WINNER

The Shelly Co., Southern Division, an Oldcastle Materials Co.

Thornville, Ohio

The Shelly Co.’s award-winning project was the milling and overlay of 11.18 miles of I 70, in Franklin County. The pavement on this four-lane interstate through central Ohio was cracked and deteriorating when the job began. On average 62,000 vehicles, 26 percent of them trucks, travel the road each day.

The Shelly Co. milled 3.25 inches from the existing roadway before laying a 19 mm asphalt base course topped by a 12.5 mm Superpave asphalt surface course. The company took the asphalt milled from the roadway back to its plant where it was incorporated into all the asphalt mixes used on the project. By reclaiming the asphalt millings, the company reduced the need for virgin aggregate and asphalt binder for the project.

Company crews worked at night to minimize traffic disruptions, and laid a base coat of asphalt on all milled surfaces before stopping work each shift to ensure a smoother surface for traffic in the idle work zone.

Nighttime paving and a late project start date that delayed paving until cooler fall weather had arrived made the project more challenging for The Shelly Co. However, by using another green paving technology — warm-mix asphalt — the company achieved the desired pavement compaction and smoothness despite less-than-ideal temperatures. “Warm-mix asphalt allowed us a little more time and gave us a little more flexibility, letting us compact the asphalt more easily,” said Larry Shively, The Shelly Co. Vice President for Quality Control. “There are also some fuel savings associated with warm-mix asphalt and, environmentally, it provides better working conditions for our employees.”

“The cooperation and communication between our plant and our crews and partnering with the Ohio Department of Transportation helped us make sure that everyone was on the same page and that everybody understood what was going on,” Shively said.

Partnering was an essential element in the success of the project, said Keith Geiger, P.E., Construction Engineer for ODOT’s District 5.

Before this job even started, I had a conversation with Tim Anderson, our Operations Manager. He was very dedicated to quality and we wanted to make sure that this would be an award-winning job,” said Shively. “Mr. Anderson passed away before the job was completed, so the project became very special to us. We went into it with the mindset that it was going to be a good job, and everyone involved made it happen — the crews, the people at the plants and the technicians.”

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FINALIST

Knife River Corp. - Idaho Division

Boise, Idaho

Knife River Corp. was recognized for the rubblization, overlay, and reconstruction of 13 miles of the eastbound lanes of I 84 in southern Idaho between milepost (MP) 222 and MP 235.

“This was a very aggressive, single-year project,” said Josh Smith, Asphalt Manger, Knife River Corp. — Idaho Division. Weather was one complication. “This is a high desert area, and our plant site was up in the mountains. We started work in early April and had to move snow to get our portable plant in place. In late October, when we were finished with the project, it was snowing as we removed our plant.” The company ran crews 16 hours a day to make sure the project was completed on time.

The eastbound lanes of I 84 were shut down for the project. The company used the cement recycled asphalt base stabilization (CRABS) process. Crews pulverized the existing concrete roadway, added cement to the rubblized material, and re-graded it before laying two courses of asphalt pavement on top.

The company milled the interstate before it pulverized the pavement, removing some asphalt from the site. They incorporated that reclaimed asphalt pavement into the asphalt mixes used for the job.

The use of RAP saved enough money on the project for the state to authorize additional work. In addition to the original project work, Knife River Corp. also removed large outcroppings of rock in the median that were a safety issue. The rock was reused to fill depressions in other sections of the median.

The quality of the asphalt mixes produced for this job was exceptional; the company achieved 95 percent of the available incentive pay for the mixes. It also earned 93 percent of the available smoothness incentives.

“My goal was to get one of NAPA’s Quality in Construction awards for this project to acknowledge their achievements,” he said. “To be a finalist for the Sheldon G. Hayes award is just unbelievable. We’re very proud of how far we’ve come.”

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FINALIST

Norris Asphalt Paving Company

Ottumwa, Iowa

Norris Asphalt Paving Co. was honored for the widening, milling, and overlay of 13 miles of US 34 in Adams and Union Counties, Iowa, from the road’s intersection with Iowa Highway 148 to the western city limits of Creston. Work also included the rehabilitation of full-width rock shoulders.

“This was an asphalt road that had not been touched in about 13 years; it was very deteriorated, had huge failures, and had been patched multiple times,” said Brady Meldrem, President of Norris Asphalt Paving Co.

The company worked under traffic, paving the road during the day while minimizing disruptions to motorists. It used warm-mix asphalt (WMA) for the project mixes and agreed to participate in a WMA research study conducted by the federal National Cooperative Highway Research Program. For the study, Norris Asphalt Paving Co. ran three test sections using different warm-mix asphalt technologies.

“The purpose of the project was to study the moisture susceptibility of the pavements,” said Meldrem. “One of the few challenges that we had on this job was logistics and scheduling, making sure that the researchers who were doing the NCHRP study were able to get to the project when they needed to conduct tests.”

In conjunction with the Asphalt Paving Association of Iowa and the Iowa Department of Transportation, Norris Asphalt Paving Co. helped host a very successful warm-mix asphalt open house during construction. This allowed engineers from the DOT, counties, cities, and consulting firms to get a first-hand look at the warm-mix asphalt process and its benefits.

Norris Asphalt Paving Co. completed its work on the highway ahead of schedule, meeting incentive targets for the project’s air voids, compaction, and smoothness.

“The density was great, the road was very smooth; you just can’t say enough about it. It was a really good project,” said Scott Nixon, Resident Construction Engineer in Iowa DOT District 4’s Creston construction office.

“I think the project’s success started with the good employees on the contractor’s end, from the plant operators and the quality control personnel in the plant all the way down to the laydown crew; these were very experienced people,” said Nixon. “Their attention to detail was above and beyond, and they had good communication among their people.”


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The award is named for Sheldon G. Hayes, a founder of NAPA and the association's first chairman. Hayes spent his entire career striving for better construction techniques and improvements in the quality of asphalt pavements.