Cargill’s Anova Asphalt Rejuvenator Restores Corporate Headquarters Entry
When it came time to revitalize the more than 40-year-old entry road and parking lots surrounding its corporate campus in Wayzata, Minnesota, the Cargill team saw an opportunity to put its Anova® rejuvenator into action at home. For its world headquarters project, Cargill partnered with two local firms to execute a seamless high RAP pavement execution for both the base and surface layers.
“Although we’ve been incorporating RAP in asphalt mixes for decades, we weren’t familiar with Cargill’s work in this space prior to them reaching out for a bid,” said Robert Kuehborn, the director of materials and quality for Commercial Asphalt Company, Maple Grove, Minnesota. “We were pleased to have this reputable, global organization come to us to be a part of this high-profile project. We were impressed with the knowledge and professionalism of the team and the process was seamless from start to finish.”
Anova was mixed at the plant using a straightforward additive pump system and metered at the proper dosage based on total asphalt content in the mix. On the mid-October day of the project, air temperatures were in the lower 40s, but other than the metered Anova into the asphalt line, the mix was produced as normal around 300 degrees Fahrenheit. The asphalt was compacted at 290-295 degrees.
On this project and others in cooler locations, Anova is reported to deliver excellent compaction, helping contractors to receive density bonuses on projects. This confidence in achieving density can help extend the season and support lower production costs.
“Being local, and since this was being used on its home turf, the Cargill asphalt team was extremely helpful at every step of the way,” Kuehborn said. “Their science, best practices, and years of insight behind RAP and the rejuvenator market was really impressive. I look forward to seeing how they continue to apply this expertise and grow the Anova brand in other markets around the globe.”
Northland Paving, one of the Twin Cities’ largest commercial paving contractors, showed up with years of experience in working with Commercial Asphalt Company and served as integral partner on the project. Both companies worked closely with the Cargill Asphalt team to determine mix specs.
“Anova was new to us as well,” said Jesse Eystad, senior superintendent with Northland Paving. The crew followed a lay-down process that was no different than a regular job. Eystad was pleased that no additional training or different equipment was needed when working with the 45 percent RAP Anova rejuvenated mix. For compaction, Northland used a 5-ton Dyanapac CYCC1300 roller on initial breakdown, then a Cat PS-105B with rubber tire behind the breakdown, then completed with a 3-ton Hamm HD12VV to finish the mat.
“It was a great experience working with Cargill and Commercial Asphalt Company on this as it gave us a chance to see how a newer product in RAP can perform,” Eystad said. “I think we’re going to see more and more RAP projects come our way, so having more options and insight to work with, the better positioned we’ll be to stay competitive and able to offer the latest in paving technology.”
In fact, according to the Federal Highway Administration, there are nearly 3 million miles of paved public roads in the United States containing 18 billion tons of asphalt mixes. And since nearly all asphalt pavement from existing roads is recyclable, the industry has already been taking advantage of the huge opportunity it has with RAP.
While increased RAP percentages in mix designs and use of the rejuvenators are gaining momentum around the world, some road construction firms are still new to the process. Not all contractors have had the chance to work with the technologies yet because of client specs and other regulatory factors.
“We’ve been laser focused on refining our rejuvenators and mixes over the last four years and are seeing some amazing growth and industry acceptance worldwide,” said Justin Black, Cargill’s global category leader, road construction. “Our team has really stepped up to advance rejuvenator technology for the entire industry. Our scale, global supply chain and expertise is proving to be a real asset for our customers to help meet their business objectives. We’re on the ground with our paving partners at every step of the way, finding the best solutions for mixes, application techniques and ways to lower cost.”
Cargill’s Asphalt team also collaborated with the Cargill Office Services team and its construction partners to help achieve a more efficient approach to meet overall corporate goals.
“We had been planning this project for a long time and were looking forward to working with Cargill’s asphalt specialists to ensure we had the best solution,” said David Hromadko, senior project manager at Cargill’s headquarters in Wayzata. He managed all phases of the project from pre-planning through construction. “It’s a great benefit to Cargill to have the opportunity to install one of our own products into a project like this at our world headquarters. It’s a great opportunity to showcase one of our innovations to our customers.”
The project’s general contractor, Greiner Construction, worked to oversee the entire campus update. Together, Cargill and Greiner Construction collaborated to implement the overall design including the roadway, upgraded parking lots, loading dock, lighting, landscaping, concrete work and other improvements on the corporate office grounds.
Cargill hired Braun Intertec to perform the geotechnical services, which gave design clarity to Loucks Associates, who is the architectural/civil engineering firm. Braun Intertec also performed all of the special inspections required for each phase of work.
The project followed strict Minnesota Pollution Control Agency requirements for storm water management and protection planning for earthwork projects. Given its location within a heavily wooded area near Lake Minnetonka, there was a comprehensive replanting plan that exceeded code requirements by the city.
“From my perspective and knowledge of the Anova product and RAP process, we will be getting a road system that will be stronger, and will last longer than a traditional mix design and the natural color of the asphalt (black) will be maintained much longer, giving it an appearance of being new and fresh,” Hromadko said. “I am looking forward to having our employees and guests experience this top-notch project.”