The I-894 Paving Blitz was an impressive feat of precision, teamwork, and innovation. Over two intense weekends, our team executed a full freeway closure, overcoming significant challenges and delivering outstanding results. In just 16 hours, we milled over 67,000 square yards of roadway, and within 19 hours, we paved 10,000 tons of asphalt—an extraordinary display of efficiency. With threats of inclement weather and logistical hurdles, our commitment to detailed planning and seamless execution ensured the project stayed on course from start to finish.
PROJECT DETAILS
- Full freeway closure for 54 hours allowed uninterrupted operations.
- 67,000 square yards of milling completed in less than 16 hours using 3 milling machines.
- 10,000 tons of HMA (Hot Mix Asphalt) paved in under 19 hours using 2 pavers simultaneously.
- 86 trucks on-site during peak trucking to maintain constant material flow.
- 3.26 miles of roadway paved with precision and speed.
- 50+ Walbec team members on-site, including milling, paving, quality control, and management.
- Round-the-clock plant operations ensured consistent material supply.
Despite these high demands, our team faced and overcame several obstacles. During the first weekend, we raced to finish key operations before a rainstorm arrived. The following weekend presented challenges with trucking routes and equipment breakdowns, which we resolved swiftly thanks to our thorough contingency plans. These situations highlighted the importance of preparation, allowing us to adapt and continue without delays.
Our use of innovative techniques and cutting-edge equipment elevated this project. The 54-hour closure permitted full-width paving, a method rarely used in freeway projects due to typical traffic limitations. Additionally, the Vogele Super Paver, which can pave two lanes at once, dramatically reduced longitudinal joints, enhancing the overall quality and durability of the roadway.
This project is a testament to the power of advanced planning, innovation, and collaboration with the Wisconsin Department of Transportation. The I-894 Paving Blitz sets a new standard for efficiency, scale, and excellence in paving operations.
