Lightweight Fill XPS Extruded Polystyrene Insulation Board

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Lightweight FillXPS Extruded
Polystyrene Insulation
Board
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Project Information Year 1

• Constructed in 2006 in Valley City District (1st
  Year of 2 Year Project)
• AC-TIP-RSN-2-281(026)030
• Hwy 281 from Edgeley to Jct ND 46
• Widening and Selective Grading
• Replace 4 Box Culverts Extend 1 Box Culvert

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Project Information Year 2

• Constructed in 2007 (Year 2 Project)
• Mine Blend and Hot Bituminous Pavement
• Add 12 inches of Aggregate Base for the Mine
  Blend Process
• Add 5 inches HBP Surfacing

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Problem Area

• Bonehill Creek
• Structure Number 281-044.251
• Existing Triple 12 x8 x104 Box Culvert
• Structural analysis indicated Existing Embankment
  Maximum Allowable Dead Load
• So the added material needed for the 2007 project
  would exceed the Allowable Dead Load

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PSE Plan Review

• Reconstruct or Regrade about 2600 feet of roadway
  over Bonehill Creek
• Located at low point of sag vertical curve
• Remove entire surfacing and aggr base
• Remove sufficient embankment to allow for dead
  load increase during Year 2 project
• Very Expensive, Increased Time, Increased
  Inconvenience to public.

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Proposed Solution

• Use Light Weight Fill to compensate for added
  depth weight of material needed in the 2007
  project
• Researched by Materials Research and K.L.J.
• XPS Extruded Polystyrene Insulation Board

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XPS Extruded Polystyrene Insulation Board - Plan
Note Requirements

• The polystyrene shall meet standards of ASSTHO
  M230-98
• Shall have a minimum compressive strength of 25
  PSI, ASTM D1621
• Each layer or sheet shall have a maximum
  thickness of 4
• Use metal connector plates or construction
  adhesive between layers to reduce sliding
• Each layer laid perpendicular to previous layer

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Typical Section
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18 Depth x 56 Width x 40 Length
3 Sand Bedding
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As Built Details

• 2 x 4 x 8 Sheets
• Total of 9 Layers
• Used Builders Choice 290 - Multipurpose
  Construction Adhesive for in between layers

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Cost Summary

• Total quantity was 40,320 Board Ft or 125 cubic
  yards
• Total Cost for all work was 64,100
• Less than the cost to regrade 2600 feet of
  roadway
• But 513 per cubic yard !!
• So makes sense to use only in the right situation

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Questions or Comments