road construction | Crossroads

Lightweight Fill (LWF) materials—including Tire Derived Aggregates (TDAs), expanded shale/clay, foamed glass, and recycled glass aggregates—show strong potential for sustainable road construction, yet important knowledge gaps remain. Their environmental impacts, long‑term performance, and construction requirements are not fully understood, especially under Minnesota’s freeze‑thaw cycles and high groundwater conditions. Concerns such as leachate production, potential trench settlement, and challenges faced by local road departments highlight the need for further investigation.

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This research seeks to address these gaps by reviewing existing practices, evaluating both environmental and mechanical performance, and developing data‑driven recommendations for using LWF materials in road construction. A detailed assessment will help clarify how these materials behave in pavement structures and embankments and how they interact with water‑sensitive environments. A decision matrix will be used to compare LWF materials and support future project planning.

To achieve these goals, the study will evaluate environmental impacts such as leachate risks, analyze long‑term structural integrity, and conduct Life Cycle Assessment (LCA) and Life Cycle Cost Analysis (LCCA) to assess sustainability and financial feasibility. The research will also develop recommended construction techniques that improve performance and support Minnesota’s climate goals and broader sustainability initiatives.

“Lightweight fill materials show promise for sustainable road construction, and Minnesota looks to learn from what has been done previously,” said Andrew Witter, Sherburne County Public Works Director and County Engineer. “This project will evaluate how these materials behave in local conditions and develop guidance for local counties and cities. The results will help agencies make informed decisions for the benefit of the transportation infrastructure in Minnesota.”

The Objectives:

Document existing research and practices related to LWF materials in road construction.
Evaluate the environmental impacts of LWF materials, focusing on leachate risks and interactions with water-sensitive environments.
Analyze the long-term performance and structural integrity of LWF materials in both pavement structures and embankments.
Compare LWF materials in a decision matrix to guide future project decisions.
Perform Life Cycle Assessment (LCA) and Life Cycle Cost Analysis (LCCA) to assess the sustainability and financial feasibility of LWF materials.
Provide recommendations to develop construction techniques that optimize the use of LWF materials and align with Minnesota’s climate goals and broader sustainability initiatives.

Project Details:

Estimated Start Date: 06/25/2025
Estimated Completion Date: 06/30/2027
Funding: Local Road Research Board
Principal Investigator: Michele Lanotte
Co-Principal Investigators: Angela Farina
Technical Liaison: Andrew Witter

Details of the research study work plan and timeline are subject to change.

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Soil carried away in stormwater runoff from road construction sites can pollute lakes and rivers.

Stormwater settling ponds provide a place for this sediment to settle before the water is discharged into local bodies of water. However, since stormwater ponds have limited space, a mechanism is needed to remove clean water from the pond to prevent the overflow of sediment-laden water.

MnDOT-funded researchers have designed temporary stormwater ponds with floating head skimmers that can remove clean water from the surface of the settling pond, using gravity to discharge water into a ditch or receiving body.

The Marlee Float from the SW Fee Saver is one of five currently available floating-head skimmers that researchers identified. — The Marlee Float from the SW Fee Saver is one of five available floating-head skimmers that researchers identified.

This is a new approach for MnDOT and Minnesota cities and counties, so research was needed to provide practical guidance for how to use these devices on construction sites.

“This was a small-scope implementation project for professionals to use as they design temporary stormwater ponds that meet state parameters,” said Dwayne Stenlund, MnDOT Erosion Control Engineering Specialist.

A new MnDOT study identifies five methods for “skimming” stormwater ponds that can improve a pond’s effectiveness by 10 percent. MnDOT researchers also created designs for temporary stormwater ponds on construction sites with the capacity to remove approximately 80 percent of suspended solids.

These designs will help contractors meet federal requirements for stormwater pond dewatering. Researchers also determined how often a pond’s deadpool must be cleaned, based on watershed size and pool dimensions.

“When sediment settles, it’s hard to determine when to clean out a pond. Based on the density of the sediments in the Minnesota River and the loading rates we computed, we were able to calculate how often we need to clean out a pond so sediment doesn’t reach the height of the skimmer,” said Joel Toso, principal of Wenck Associates and a consultant for the project.