Colorado Winters are notoriously extreme, with freezing temperatures and harsh climates that take a toll on infrastructure.
One of the most visible effects of these conditionsis the damage to roads, which develop cracks, reducing safety and leaving the public with inefficient transportation networks.
Addressing these challenges required innovative solutions, and this past summer, th ecity of Colorado Springs (COCS) undertook a road resurfacing project on Austin Bluffs Parkway in Colorado Springs.
The Austin Bluffs Parkway project was a collaboration between COCS and Cutler Repaving, a company with extensive experience in road resurfacing.
“The climate in Colorado is brutal on asphalt pavements,” said Todd Gonser, the western states manager at Cutler Repaving. “High elevation, arid environment and between 100 and 200 freeze/thaw cycles per year can rapidly stress a pavement.”
Cutler Repaving used hot in-place recycling, a process that minimizes waste and maximizes resource utilization by recycling existing road materials directly on-site.
This innovative approach earned the project the Hot In-Place Recycling Award from the Asphalt Recycling and Reclaiming Association (ARRA), recognizing its excellence in sustainable road construction.
Cutler Repaving had partnered with other local agencies and DOTs before this project.
Their proven track record, combined with the expertise of their team, ensured the Austin Bluffs Parkway resurfacing would be completed on time and within budget. Joining Cutler Repaving in this endeavor were Kiewit Infrastructure, Continental Milling, Safeguard Traffic Control, Chacons Trucking and RoadSafe Traffic Systems, each contributing specialized skills and resources to the project.
“Completing this project in 23 working days was made possible by fantastic teamwork between Cutler Repaving personnel and sub-contractors,” said Gonser. “Cooperation and coordination with city of Colorado Springs staff (Michael Hensley and William Croff) was key to the success.”
Work began on July 1. The scope of the project was ambitious: resurfacing approximately 80,000 square yards of full-width milling and hot in-place recycling, alongside the application of more than 6,700 tons of new hot mix asphalt pavement across two key arterial roads in the city.
Many believe that hot in-place recycling is a superior method for road repair because of its cost-effectiveness and reduced environmental impact. Traditional road repairs often require significant amounts of new materials and generate more waste, but hot in-place recycling uses only half the amount of new materials by recycling the existing pavement.
Hot in-place recycling conserves resources and reduces the overall project timeline, minimizing traffic and congestion.
Originally, the project was planned as a conventional mill-and-overlay operation. However, city staff in Colorado Springs identified an opportunity to stretch the budget further by adopting the hot in-place recycling method.
This approach aligned with the city’s goals of addressing environmental concerns and minimizing the impact on the traveling public. By leveraging this technique, the city ensured that taxpayers saw tangible results from their contributions while also setting an example for sustainable infrastructure practices.
The project began with scoping in early 2024, during which engineers evaluated the existing pavement conditions and developed a plan tailored to the specific challenges of Austin Bluffs Parkway.
Initially, the pavement section was designed for 2-inch mill and overlay. However, crews utilized the hot in-place recycling method, which recycles 1.5 inches of existing asphalt pavement followed by an integral 1.5 inches of overlay. This reduced the duration of lane closures, minimizing traffic and increasing safety for the crew.
One of the challenges faced during the project was the poor condition of the existing pavement. Severe surface issues such as block cracking, alligator cracking, transverse thermal cracking and delamination were prevalent throughout the roadway.
To address these problems, Cutler Repaving recommended a comprehensive random coring plan to assess pavement thickness and distress levels. This assessment allowed the team to tailor their approach, ensuring the resurfacing addressed the underlying issues and provided a durable solution.
Using hot in-place recycling brought multiple benefits to the project. By recycling materials in place, the method reduced the need for hauling and disposing of old asphalt, cutting down on transportation costs and emissions.
“With typical maintenance treatments, such as crack seals and patching, we can plan to see 10-15 years before another resurfacing treatment is needed. It should be a long time before this pavement would need full reconstruction,” said Gonser.
Additionally, the process conserved resources by reducing the amount of new asphalt required. The streamlined workflow also allowed crews to complete the resurfacing quickly, reducing traffic disruptions and improving safety for workers and motorists. Motorists saw their tax dollars at work as the efforts of the team brought new life to Austin Bluffs Parkway.
The project demonstrated the potential for sustainable infrastructure solutions to meet the challenges posed by Colorado’s harsh winters.
The project was completed on Aug. 5. Not only did it improve the safety and efficiency of the roadway but also set a standard for future road repair initiatives in the region.
The Hot In-Place Recycling Award from ARRA underscores the significance of this project as a model for innovation and sustainability in road construction.
“Cutler Repaving is extremely honored and proud to receive this honor,” said Gonser. “It highlights the hard work and dedication between Contractor and Agency to provide a long-lasting, cost-effective, enviro-friendly project for the people of Colorado Springs.”
By embracing cutting-edge methods and prioritizing environmental stewardship, Colorado Springs and its partners have shown how public infrastructure projects can achieve lasting impact with budget constraints and environmental goals in mind.
As Colorado continues to contend with the challenges of maintaining its roadways, projects like the Austin Bluffs Parkway resurfacing offer valuable lessons. The collaboration between COCS, Cutler Repaving and their partners highlights the importance of expertise, innovation and community support in addressing infrastructure needs.
Through the effective use of resources and a commitment to sustainability, this project has set a precedent for future endeavors, ensuring that Colorado’s roads remain safe, efficient and resilient for years to come. RB
