Michigan Paving compresses a 3-year U.S. 131 reconstruction project into 2 years with innovative approaches and a design-build plan, using heavy loads of material and modern technology to improve safety, traffic flow, and road longevity on this vital highway in Michigan.
U.S. 131 is a vital highway that stretches 270 mi. from Michigan's southern border through cities like Grand Rapids, Kalamazoo, Portage and then through farmlands and forests, terminating in the popular summer vacation areas in the northern part of the state.
Just south of Grand Rapids, a city of about 200,000 people, this freeway was showing its age. The road was originally concrete and had been overlaid with asphalt many times.
A 3.1-mi. section of the road has reached the end of its service life and is being replaced by Michigan Paving and Materials, a CRH Company, based in Grand Rapids. Michigan Department of Transportation (MDOT) has worked with the company on a design-build plan that will save time, money and headaches for drivers.
"Design-build is somewhat new in this area, but the DOT elected to use this approach to allow fixability to the contractors, ultimately saving time and money going this route," said Chad Wilson, project manager of Michigan Paving and Materials. "We decided on some innovative approaches to managing traffic and plan to complete the work in two years rather than three. In recent years, we have seen a pandemic break out, oil prices rise and material costs go up. Because all kinds of unexpected things can happen, we decided to try to get the job done quicker."
This meant that the company became the construction manager at risk and forged ahead with what it felt was a solid plan.
"We didn't get the final approval from the DOT until August 30 and, by that time, we were two-thirds finished with the southbound median, shoulder and fast lane. I admit, we had a few nervous moments," Wilson said.
During the first month of the project. workers spent widening streets and strengthening the shoulders of U.S. 131 so traffic could be moved to the outside lanes and new lanes added on the inside in both directions.
The remainder of the project will be completed in 2025. The project should be completed by the end of the year with miscellaneous tree plantings and punch list items to be completed in spring of 2026.
"By using the middle-out approach, we have been able to construct the median, the barrier wall, the valley gutters as well as the inside shoulder and the fast lane for southbound traffic," said Wilson. "In addition, we have completed the temporary pavement for crossovers at the ramp locations and both ends of the project."
The project will cost $64 million and will require 136,00 tons of asphalt. Workers will use about 350,000 cu. yds. of concrete for pipe and barrier walls with 12,000 cu. yds. of material for embankments and 230,000 cu. yds. of aggregate and material of subbase for the rebuilt roads.
Workers will run traditional paving equipment, rollers and a material transfer vehicle for the paving operations. Bulldozers, excavators and articulated trucks will make things happen for grading and hauling.
50 Tons of Asphalt
The team will use one slightly unusual vehicle — a truck capable of hauling 50 tons of asphalt at a time — which releases material ahead of the paving train. Heavier loads are allowable in Michigan because of the state's history of using heavy loads of material and finished cars for the auto industry. Because workers could haul heavier loads of asphalt, the paving process was sped up.
Building two lanes of traffic in the median has its advantages but adds complexity. The median was a simple grass strip, but the new one will contain a concrete median wall with new storm drains. The construction team achieved a major milestone by completing much of the storm drain work during the 2024 paving season.
Working in the median can be tricky since construction vehicles must accelerate and decelerate in traffic's fast lanes.
"We are doing most of our work behind concrete barriers but have created multiple gaps in the walls for safe entrance and exit for our vehicles," said Wilson.
The construction team also is using a dynamic safety messaging system to alert drivers about changes in the work zone and traffic delays ahead. Too often, drivers find out about the construction late and even follow trucks into the work zone.
The dynamic messaging system uses radar to survey the traffic as it is happening and send information to message boards as much as 6 mi. away. These message boards give drivers plenty of time to adjust their speed before they reach the construction zone.
Other technology is now becoming commonplace in construction zones. Total station robots, rovers and GPS systems connect the machines electronically and enable workers to achieve accuracy that would have been unthinkable a few years ago.
"Often, we are able to place the material to within 0.1 inch of where it is supposed to go," said Wilson. "This saves material and the time for our team to team to place it accurately."
The final road profile will be a base of 18 in. of sand and 6 in. of gravel, with 10.25 in. of Superpave asphalt. The surface will contain a polymer-based liquid 70-28P. This mixture will give the flexibility needed to survive the summer heat, which often is in the mid-80s, and the winters where temperatures often plunge to single digits.
Road building in the north means contending with cold temperatures.
"We are building a base of 18 inches of sand, which will put us above the freeze-thaw level and avoid frost heave in the winter."
The construction team has dug as deep as 30 ft. to insert box culverts in the median. This will allow culverts 10-12 ft. tall to handle water runoff and keep the roads and drivers safe.
"We believe we are building a road that will be usable for the next 50 years," said Wilson.
Adding an additional lane and medians will bring more safety and aid the traffic flow. U.S. 131 will soon have a brighter future for commuters, truckers and vacationers as they enjoy "Pure Michigan." CEG
Chuck MacDonald
Chuck MacDonald is an editor, blogger and freelance feature writer whose writing adventures have taken him to 48 states and 10 countries. He has been the editor for magazines on pavement construction, chemicals, insurance and missions. Chuck enjoys bicycling, kayaking and reading. He graduated from the University of Missouri with a degree in journalism. Chuck lives in Annapolis, Md. with his wife Kristen. They have seven grandchildren.
https://www.linkedin.com/in/chuckmacdonald/ Read more from Chuck MacDonald here.
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