An impressive transformation occurred on Samaria Road in the heart of Monroe County, Michigan, earning the county’s Road Commission the prestigious 2024 Perpetual Pavement by Conversion Award. The award celebrates innovative paving solutions that ensure longevity and durability in asphalt roads. The recognition from the Asphalt Pavement Alliance (APA) highlights not only the effectiveness of the project but also the significant contributions made by Gerken Paving, Inc., the prime contractor responsible for turning an old, failing roadway into a model of modern pavement engineering.

A Road in Dire Need of Repair

Initially constructed in the 1960s, Samaria Road suffered from severe structural issues. Without tie bars to transfer load between the 8-inch-thick concrete slabs, more than ten miles of the road had become dangerous to drivers and heavy vehicles alike. Crumbling patches connected slabs, and nearly every longitudinal and transverse joint failed. The situation deteriorated to the point where trucks refused to access local farms for produce pickup, significantly impacting the local economy.

“We’d gotten a lot of complaints on this road, and there were serious issues with it,” said Randy Pierce, the Road Commission’s managing director at the time. “Even our insurance company wanted to get the work done because there were blown tires and a lot of people driving on the shoulders and roadsides just to avoid the pavement.”

Recognizing the urgency, the Monroe County Road Commission secured supplementary financing in 2013 to undertake an ambitious project during the 2014 construction season. The goal was to reconstruct Samaria Road with a more sustainable and durable pavement solution.

The Full-Depth Reclamation Solution

Under the guidance of the Monroe County Road Commission, Gerken Paving, Inc. employed full-depth reclamation (FDR) methods for the project. The innovative approach involved removing the existing failed concrete pavement, crushing it, and repurposing the materials to create a stabilized reclaimed asphalt pavement (RAP) base.

“We were trying something new for Monroe County,” said Pierce. “We took the old concrete out and reclaimed the whole structure.”

By utilizing engineered asphalt emulsion and a combination of crushed concrete and aggregate, the team crafted an asphalt-stabilized base layer topped with two additional layers of hot-mix asphalt. The result? The new pavement could withstand increased traffic loads while maintaining exceptional structural integrity.

“People need to take a good look at this project,” foresaw Gerken’s Dean Breese during the project. “It demonstrates a very viable way to replace a road. I have a feeling it’s going to perform very well.”

A Testament to Quality and Sustainability

The impact of the Samaria Road Improvement Project was immediately apparent. Traffic quickly rose from 3,000 vehicles daily to an impressive average of 4,350 today, with commercial traffic now constituting 20 percent of that total. The increase reflects the road’s improved condition and signifies renewed economic activity in the area. Despite the significant growth in traffic volume, the road remains in excellent structural condition.

By incorporating a stabilized reclaimed asphalt pavement layer topped with hot-mix asphalt, Gerken Paving and the Monroe County Road Commission proved that smart investments in infrastructure yield dividends for taxpayers in terms of quality, longevity, low maintenance costs, and overall sustainability.

Gerken Paving’s Michigan office managed the contracting, with area manager John Yocom, project manager Mark Krieg, and asphalt paving foreman Scott Breier overseeing the work.

Engineering analysis confirms the new pavement meets Perpetual Pavement requirements, validating the project’s long-term sustainability and cost-effectiveness.