Ontario Paver of the Year

By Andy Bateman, Engineering Editor

Aecon Construction & Materials Ltd.'s Brian Morris proudly displays the Paver of the Year Award and the Southwestern Region Award. Both awards were presented to the company at the Ontario Road Builders Association's 76th Annual Convention.

Quality roadbuilding was once again acknowledged at the Ontario Road Builders' Association (ORBA) 76th Annual Convention, held this year February 3-5, 2003 at the Fairmont Royal York Hotel in Toronto. Award winners, including 2002 Paver of the Year, are selected annually for outstanding performance in each of the Ministry of Transportation of Ontario's five regions.
      The prestigious 2002 Paver of the Year Award and the MTO's Northern Region Award went to Aecon Construction and Materials Ltd. for the company's work on MTO contract number 2000-0235. Located on Highway 69 at Mactier, this contract was valued at $32 million and included grading, drainage, granular base, hot mix paving and structures on a stretch of Highway 69, from 2.0 km north of Muskoka Road 12 northerly for 10 km.
      The majority of this project is new alignment and was constructed in primarily closed road conditions over a two-year period from November 2000 to October 2002. Extreme weather swings over the course of 2001 included a bitterly cold winter, hot dry summer and wet fall. Aecon's Brian Morris attributes the overall success of this project to the efforts of the project's construction team, consisting of the Carillon Construction Canada, Aecon Construction and Materials Ltd. and Leo Alarie and Sons Ltd. joint venture (CAAJV), the contract administration team of Tulloch Engineering and Surveys, as well as the contract control team of the MTO. Morris highlights extraordinary cooperation within this team that enabled quality control to be managed in a collaborative, rather than confrontational, environment. One of the project's many challenges was its location in an environmentally sensitive area containing the endangered Massassauga rattlesnake. Working closely with Ontario's Ministry of Natural Resources, the CAAJV implemented several measures to protect the snakes and was rewarded for its efforts with the presentation of an environmental award by the MTO. To tackle the major excavation work on this project, heavy equipment was brought in including an Hitachi EX 1100 excavator supplied by JV partner Leo Alarie and Sons Ltd. Morris reports that mass rock excavation work continued round the clock in order to expedite the job schedule, improve site access, and facilitate work dependent on subgrade completion such as structure construction, culvert placement, and granular placement.

Roadtec SB-2500 Shuttle Buggy feeding Caterpillar AP-1000 paver on award-winning contract.

      Innovative solutions on the job included layout and grade control utilising the latest Trimble Global Positioning System (GPS) survey technology instead of the traditional staked survey. GPS technology was also used in a dozer application where Trimble's survey system supplied the operator with finished subgrade elevations in relation to the dozer blade. Here, the GPS survey system was said to be particularly useful during the initial stages of the job when survey points were difficult to both locate and access. Trimble's BladePro system, installed on a grader, was an additional grade control innovation used on the project. This system provided elevation control of the grader blade during fine grading by utilising signals transmitted from a known point. In operation, the system was said to be extremely accurate and to have made a direct contribution to the overall smoothness of the pavement.
      Hot mix asphalt was produced by Aecon's 360 tonnes/h capacity portable Gencor drum plant utilising aggregates manufactured on site by Leo Alarie and Sons Ltd. Paving equipment for the job consisted of Aecon's Roadtec SB-2500 Shuttle Buggy feeding two Caterpillar AP-1000 pavers working in echelon and fitted with Topcon's grade control system. The Caterpillar compaction fleet behind the paver included a CB-634 dual unit in the breakdown position, a PS-300 rubber tired secondary compactor and a Cat CB-534 finishing roller. Each completed two passes to achieve 94 per cent average density. Materials quantities included 52 000 tonnes of HL-3 Modified surface course hot mix asphalt and 25 000 tonnes of HL-4 Modified base course as well as 173 000 tonnes of Granular A and 267 000 tonnes of Granular B. Concrete volumes included 1 500 m3 of 50 MPa and 1100 m3 of 35 MPa mix, supplied by Parry Sound Ready Mix Concrete. Additional job quantities included 290 000 m3 of earth excavation, 900 000 m3 of rock excavation and the placement of 1100 m of 1800 mm x 1200 mm precast culvert. Key Aecon people involved in the project were Cara Peters, project engineer and asphalt paving superintendent Glen Pye.

Southwestern Region Award
     Aecon Construction and Materials Ltd. is certainly doing something right, also taking the Southwestern Region award for its performance on MTO contract 2001-3004 to scoop two awards for the second year running. This contract, on Highway 400 at Barrie, was valued at $6 Million and extended from 1.0 km south of Essa Rd. northerly to 0.5 km north of Willow Creek. The job took just two and a half months between April and July last year, with the majority of work completed at night. It involved milling all lanes of the highway to a depth of 50 mm, plus the milling of lane two (the centre lane) a further 50 mm for most of the length of the project.

Aecon used two pavers in echelon to carry out the asphalt surfacing operations on their award-winning contracts.

      Existing guide rail was also removed and replaced. Two interchanges, Essa Rd. and Dunlop St., required full depth removal of asphalt and curb and gutter, and this work was completed during full interchange closures over two weekends. After milling, the pavement was reinstated with a 50 mm lift of heavy duty binder course (HDBC) in those areas of lane two that were milled the extra 50 mm, followed by a 50 mm lift of dense friction course (DFC) covering the entire highway. Milling and asphalt quantities included 360 000 m2 of asphalt milling, 11 000 tonnes of HDBC and 52 000 tonnes of DFC. Here, Morris cites cooperation between the Ministry of Transportation, the Contract Administrator (HCIO) and Aecon as one of the main reasons the project was completed successfully. For example, a change proposal initiated by Aecon and accepted by the Ministry, improved project safety, both for construction zone workers and the travelling public.
      The contract was originally staged such that either the northbound or southbound lanes would be closed entirely each night, with traffic in the closed direction detoured through the median. This scenario would result in opposing traffic being on the same side of the highway and separated only by plastic TC-54 barrels. After several discussions and positive input from both the Ontario Provincial Police and the Ministry of Labour, it was decided that Aecon's change proposal was the safest and most cost efficient method of constructing the highway, particularly with the night work involved.
      Under the agreed staging change, both northbound and southbound lanes remained open and work was completed utilising lane restrictions in the conventional manner. The staging change delivered several other benefits besides improved safety. For motorists, the change allowed on and off ramps throughout the city to remain open, while for Aecon, it facilitated timely delivery of asphalt and other materials to the site. A second asphalt paver was brought on site, allowing echelon paving (initiated and accepted under another change proposal) to be done wherever possible. At other times, one paver could complete intersection tie-in work while the other paver continued main line paving.
      Roto Mill Services Ltd. of Brampton completed the milling job utilising two CMI pavement profilers. Unit 1 was a CMI PR-1050, powered by a 783 kW (1050 hp) engine making a 3.81 m wide cut, while Unit 2 was the 1050's smaller stablemate, the PR-800, powered by a 597 kW (800 hp) engine and milling a 2.18 m wide cut. Aecon's paving train was similar to the equipment spread utilised on the Northern Region Paver of the Year contract and consisted of a Roadtec SB-2500 Shuttle Buggy feeding Caterpillar AP-1000B pavers fitted with Topcon grade control systems. The Caterpillar compaction fleet following the paver included a CB-634 breakdown roller in the breakdown position, PS-300 pneumatic unit in the secondary position and a CB-534 finishing roller. Each completed two passes to achieve 94 per cent average density. Morris notes that the average production rate of asphalt placed on this job was just over 200 tonnes/h, adding that the SB-2500 facilitated maximum productivity. Hot mix asphalt was supplied from Aecon's portable asphalt plant, a Gencor drum mix unit rated at 360 tonnes/h and strategically located at the intersection of Highways 11 and 93 near the north end of the project.
      Aecon's senior project superintendent on this contract was Gary Kmith, with Jim Young in the dual roles of daily site superintendent and quality control plan administrator. Junior Lake was asphalt superintendent responsible for paving operations.

Northwestern Region Award
      The MTO's Northwestern Region award was won by Bruno's Contracting (Thunder Bay) Ltd. for contract number 2001-0215. This contract involved reconstruction of a section of Highway 17 northwest of Thunder Bay, from 14.3 km west of the Raith West Junction westerly for 18.8 km. Valued at $4.56 million, the job lasted six months from April to September last year and included grading, drainage, granular base and paving. The job was noteworthy as the first contract in Northwest Region to include a heavy duty binder course (HDBC) asphalt mix.
      Unusually cold spring temperatures coupled with severe flooding in the region hampered early site work. The weather also impacted on aggregate delivery, as the supplying quarry was a substantial distance from the highway with difficult access. At the quarry itself, another challenge was the familiar problem of effectively screening wet feed material to produce spec fine aggregates. During the summer months, additional challenges came in the form of heavy construction zone traffic as this section of the Trans-Canada Highway is close to a cottage area and subject to weekend holiday traffic.
      Materials for the job included 95 000 tonnes of Granular A and 19 000 tonnes of Granular B, followed by nearly 50 000 tonnes of hot mix asphalt. Mix quantities included 22 600 tonnes of HDBC and 26 300 tonnes of HL4 (modified), produced by a quarry based Barber Greene portable drum plant rated at 250 tonnes/h. On site, Bruno's paving train consisted of a Roadtec SB-2500 Shuttle Buggy feeding a Vùgele America Pro-Pav Swiftrac paver, followed by a Hamm HD 110 roller for breakdown and a pneumatic Caterpillar PS-300B finishing roller. The compactors made two to three passes each to achieve densities of 94%. Company secretary-treasurer Silvio DiGregorio reports that a dedicated team of employees including superintendent John Arnosti, assistant superintendent Danielle Bartlett and Quality Control manager Bernie Prevost take the credit for delivering success on this project.

Eastern Region Award
      Dufferin Construction Company was the MTO's Eastern Region award winner was for its work on Highway 401 near Morrisburg. MTO contract 2001-4018 covered a section of the Eastbound Lane (EBL) from 0.9 km east of Carmen Rd. easterly to 0.95 km west of Upper Canada Rd. and was valued at $5.4 million. Lasting from May 5th to October 15th 2002, Dufferin's work included drainage, milling, grading, bridge rehabilitation and paving. Hot mix was supplied by Dufferin's 360 tonnes/h capacity portable CMI drum plant, set up at Iroquois, and delivered by Red River LB (Live Bottom) trailers having 35 tonnes of payload.
      On site, Dufferin's paving equipment included a Roadtec SB-2500 Shuttle Buggy, a Caterpillar AP-1055 Paver, Bomag BW202AD and Bomag BW201AD compactors in the breakdown position, a Dynapac 271 secondary compactor and a Bomag BW154AD finishing roller. Asphalt mix quantities totalled 22 889 tonnes of HL1 (Modified) and 43 207 tonnes of heavy duty binder course (HDBC). Raw materials and suppliers for this contract included 64-34 Performance Grade Asphalt Cement (PGAC) from McAsphalt Industries Ltd., HDBC and base aggregates from Cornwall Gravel Co Ltd., HL-1 (Modified) aggregates from Lafarge Materials & Construction Inc.'s Brockville quarry and HL-1 Blend sand from Charlie Moore Sand. Cruickshank Construction Ltd. supplied clear stone covering sub-drains and was also subcontractor to Dufferin for drainage work. Hard Rock Paving Co. Ltd. completed surface milling. Key Dufferin people involved on the contract included district manager Michel Rodrigue, superintendent Peter Gamble and assistant superintendent Dan Beneteau.

Central Region Award
      Warren Bitulithic Ltd. won the MTO's Central Region Award for paving on the Highway 404 extension near Newmarket under MTO contract number 2000-0077. Featured in the October/ November 2001 issue of Aggregates & Roadbuilding, this paving contract marked the first time that hot mix asphalt designed to full Superpave specifications has been utilised on an Ontario 400 series highway. The paving job extended 2.4 km, from 800 m south of Davis Dr. in Newmarket, northerly to 150 m north of Green Lane (formerly Herald Rd.). Additional work included Green Lane, from Leslie St. to 74 m east of Woodbine Ave. The total value of Warren's Bitulithic's work was over $3 million and focussed on paving, while grading, drainage and other work was carried out by prime contractor Carillion Construction Canada.
      Superpave mixes were used on the southbound lanes as this section of Highway 404 will be an increasingly popular route for loaded aggregate trucks heading south to Toronto from Stouffville-area aggregate operations. Two southbound lanes, plus acceleration and deceleration lane for Green Lane and Davis Dr. respectively, were paved with three lifts totalling 180 mm. A 90 mm thick Superpave base lift of 25NMS (25 mm nominal maximum size aggregate) was followed by a 50 mm Superpave base lift of 19NMS and a 40 mm surface lift of Dense Friction Course (DFC).
      The northbound lanes were paved with the same combined thickness of hot mix asphalt as the southbound lanes (180 mm), but instead utilised conventional mixes throughout; a 50 mm lift of HL8, 50 mm of lower HDBC, 40 mm of upper HDBC and 40 mm of DFC. A fixed Astec batch plant and Standard-Haven counterflow drum plants at Lafarge Canada's Maple Yard successfully produced the Superpave asphalt mixes. On site, a Roadtec SB-2500 Shuttle Buggy fed a Caterpillar AP-1055B tracked paver fitted with a hopper insert and a 10-20B Extend-a -Mat screed. Behind the paver, an Ingersoll Rand DD110HF compactor made two passes on high amplitude and frequency, followed by a Caterpillar PS-300B rubber tired compactor making six passes and a Bomag BW164AD in the finishing position making six passes in static mode. Hot mix types and quantities included 5100 tonnes of HL8, 23 700 tonnes of HDBC, 11 000 tonnes of DFC, 3800 tonnes of 19NMS and 4700 tonnes of 25NMS mix, as well as 6300 tonnes of HL 3 on Green Lane. Fine aggregates and coarse aggregates were supplied from Lafarge Materials & Construction Inc.'s Dundas quarry while its Lafarge's Coldwater operations provided coarse aggregate for the DFC mix. Warren's team found that the treatment of Superpave mixes was generally similar to other mixes, although some adjustments were necessary to deal with the relatively coarse mixes and lift thicknesses almost double those of traditional Marshall mix types.
      Modifications at the asphalt plant yard included cold feed screen changes, while in terms of paving, Warren's Andrew Pahalan reports that the remixing provided by the Roadtec SB-2500 was reportedly essential for dealing with the Superpave mixes. In addition, rolling patterns were adjusted to achieve the required in situ compaction and an innovative hopper sampling system was developed to obtain representative samples of the thick Superpave lifts. Key people involved on the project included Rick Logozzo, construction manager-Special Projects & MTO; Mike Greco, general manager; Doug McDonald, asphalt plant manager; Dan Gillis, field superintendent; Carlo Fallavollita, general superintendent; Brian Samulewitch, Quality Control manager; Mix Designs & Sampling Hopper; Paul Lum, Superpave Mix Designs; Andrew Pahalan, Quality Control co-ordinator; Robert Bernardi, paving foreman; Phil Digiorgio, paving foreman and Rob Belanger, plant foreman.

From left to right: Gary Kmith, Aecon Construction & Materials Ltd., Southwestern Region Award Peter Gamble, Dufferin Construction Co., Eastern Region Award Hon. Norm Sterling, Ontario Minister of Transportation Tom Dziedziejko, Aecon Materials Engineering, Aecon Construction & Materials Ltd., 2002 Paver of the Year (Northern Region Award). Dan Gillis, Warren Bitulithic Ltd., Central Region Award (Absent from photo - Bruno's Contracting (Thunder Bay) Ltd., Northwestern Region Award winner).

March-April 2003 issue

Aggregates and Roadbuilding Magazine
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