By Stephany Osuji,  Office of Customer Relations 
  
                  
                  Crews install Geofoam west of the Maryland Avenue Bridge site in St. Paul  to reduce potential  long-term settlement problems. Photo by Derrick Dasenbrock  | 
               
             
           
             
            The recent Interstate 35E Maryland Avenue bridge project in  St. Paul is just one  example of MnDOT’s commitment to innovation.  Various innovative techniques, most notably the use of Self-Propelled Modular  Transporters to move the main span into place, highlighted the project.  However, a lesser-known innovation proved essential in providing stability  beneath Maryland Avenue in areas where the local soil was unstable. 
            Expanded Polystyrene, often referred to as Geofoam,  is a low-density Styrofoam commonly used as a lightweight fill on construction  projects. The foam is approximately one percent the weight of normal fill, such  as gravel or dirt, and is used where hard-to-remove organic soils would  otherwise compress when being backfilled.  
            Geofoam has become the lightweight fill of choice for  MnDOT’s Foundations Unit for several reasons, according to Rich Lamb,  foundations design build engineer. It has similar strength characteristics to  soil, but has the enormous benefit of being extremely light—1-2 pounds per  cubic foot. 
            “Using Geofoam is a long-term solution to help stabilize roadways over compressible soils  where it would be expensive and hard to remove the poor soils,” said  Joey Lundquist, Metro District Design engineer. 
            During the Maryland Avenue Bridge project, Geofoam was placed  under the pavement along Maryland Avenue and the ramps to reduce potential  long-term settlement problems while protecting the existing utilities on  Maryland Avenue, just west of the new bridge.  
            Construction crews installed the Geofoam by first excavating  the area where the foam would be placed. The blocks were then installed in a staggered pattern until the foam reached  the appropriate height. Once the geofoam was in place, it was covered with a thin  plastic barrier called a geomembrane. The geomembrane protects the Geofoam from  petroleum-based spills. Finally, the foam was backfilled with appropriate  grading material and ready for concrete paving. 
            Although the upfront material cost is high at $50-$80 per  cubic yard, Geofoam has proven to have a high return on investment. It also has  a track record of being an effective material when dealing with embankments and  poor soils, according to Lamb. 
             “With minimal excavations,  we can now construct roadway embankments with Geofoam and basically have no  load imparted on soft, organic soils,” Lamb said. “This means virtually no  settlement and safe, smooth roadways.”   
            Another benefit of Geofoam is how quickly it can be installed,  which saves on construction time. Each 4-by-8-by-3 foot block weighs 127 pounds and can easily be  handled by four workers, according to Lamb. As much as 1,000 cubic yards  can be placed each day. 
            “Without Geofoam on the Maryland Avenue Bridge project, the  contractor would have had to perform very deep and costly excavations to remove  the poor soils,” Lamb said. “This may have extended the construction time,  something that was a great concern for such a high-profile project.”  |