rubmeister100 said:
The problem with the roads, wait for it , is consultants.
There are so many consultants and engineers using up sooooo much money consulting, reporting and inspecting that a lot of the money never finds its way into gravel and concrete and asphalt.
These consultants get in REALLY tight with the MTO clique and in with the Milelr Paving/Warren B/Beamish mafia. There is no chance for anyone to get into the industry and provide some alternative competition. As a result, the overhead of these jobs goes sky high, with less tricking down into the road bed and top.
Really simple to build a good road up here. Anywhere.
For the 401, dig down eight to ten feet and pour a 12" bed of dry 20mpa concrete. Fill with granular fill (sand and stones ONLY. nothing organic) Compact in 12" lifts (layers) and top with 24" thick 25mp concrete with fibremesh reinforcement and 6% air. Roughen the surface with grooves. Top that with 4" of rubberized asphalt. You have to use and asphalt "primer" to bond the asphalt to the concrete.
It will not heave, crack or otherwise break down. Every five years (on a high use road like the 401) you'd have to grind off the asphalt and retop it.
Expensive, but it works.
Actually, consulting engineering fees for highway design usually amount to be about 2% of construction costs. Hardly significant.
Your design is flawed for the following reasons:
1. I don't understand why you would want a 20 MPA layer of concrete about 8 or 10' down when the frost level in Ontario is only about 4' down.
2. What about water that becomes trapped? Which will cause frost heaves.
3. No-one uses 20 MPA concrete ever.
4. 12" layers, try 100 mm lifts compacted to 98 SPD.
5. Fibremesh reinforcement - dunno, I don't think that would be suitable in this application.
6. I am not sure exactly what "rubberized asphalt" is MTO typically uses DFC or OFC on its highways to aid in drainage.
7. If you did a life cycle analysis you would find that for the cost of your design, you could probably build a new highway every 5 years and still be more cost effective.
The thing that kicks the hell out of highways is trucks.
One truck does as much damage to a highway as 20,000 car passes.