I-65/I-70 North Split — Faster, Stronger, More Sustainable

On a $400M INDOT interchange rebuild, the E5® system overcame winter weather, mix limitations, and labor shortages—reducing cracking by 70% and eliminating wet curing to keep the schedule and budget on track.

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Project Snapshot

Owner/Developer: INDOT
Location: Indianapolis, Indiana
Project Cost: $400M
Scope: >50 bridges; 35 lane miles of paving; 34,000 yd³ concrete
Engineer: HNTB Corporation
GC / Concrete Contractor: Superior Construction
Ready-Mix Producer: Shelby Materials
Recommended E5® System: E5® Internal Cure + E5® Liquid Fly Ash.

About Indiana & I-65

Indiana is a Midwest U.S. state known for its agriculture, manufacturing, and the iconic Indianapolis 500. Its central location makes it a key hub for transportation and logistics. Interstate 65 runs through the state from Gary to Indianapolis, continuing south to Mobile, Alabama. As a major north-south route, I-65 connects Indiana to key cities and plays a vital role in commerce and travel across the region.

The Challenge

This landmark interchange rebuild faced winter weather, mix-design constraints, and acute labor/supply-chain pressure—conditions that typically extend curing time, increase cracking and rework, and threaten on-time opening. INDOT needed a solution that would harden performance while compressing the schedule and reducing lifecycle cost.

The E5® Solution

The team deployed E5® Internal Cure with E5® Liquid Fly Ash to internally cure and densify concrete while stabilizing workability in cold conditions. The system eliminated wet curing and all curing compounds, improved abrasion resistance and FF/FL, and enabled crews to access pavements sooner than with topically treated mixes—directly attacking the project’s critical-path risks.

Products Used

Built-In Performance: The E5® System Behind the Results. This project’s outcomes weren’t accidental—they were engineered into the slab. By pairing the right admixtures and surface systems, we delivered internal curing, faster access, and a harder, more resilient finish that stands up to real-world demands.

E5® Internal Cure

Delivers internal curing that retains mix water for continued hydration, helping cut cracking and enable earlier access with no wet-curing step.

E5® Internal Cure

E5® Liquid Fly Ash

Engineered liquid pozzolan that reduces cement/SCMs and molecularly packs the matrix for lower permeability and improved finishability—critical for pavements and bridge decks.

E5® Liquid Fly Ash

34,000yd³

Total concrete placed across bridges and pavements.

35 Lane Miles

Paving scope requiring consistent workability and early access.

50+ Bridges

Structural placements with cold-weather and durability demands.

15% SCM Reduction

Embodied-carbon and materials savings via E5® LFA.

Schedule/Mix Process

By combining E5® Internal Cure with E5® Liquid Fly Ash, the team removed wet curing and all curing compounds, effectively reworking a two-step process into one. That simplification, plus improved finishing control, substantially shortened project duration while supporting quality and safety targets during staffing and supply constraints.

Performance Needs

Bridge decks and pavements needed a dense, durable matrix with controlled cracking and abrasion resistance to stand up to heavy traffic, de-icers, and freeze-thaw cycling. INDOT also required predictable placements in narrow work windows and a mix that maintained finishability and FF/FL despite winter conditions.

Project Overview

The E5® system directly addressed cold-weather, mix, and labor headwinds that typically derail large DOT jobs. Verified outcomes include a 70% reduction in cracking, elimination of wet curing, and significant cement/SCM savings—benefits that protect both the schedule and the structure’s long-term performance.

How E5® Elevated Performance

70% less cracking across placements.
Two steps into one: process simplification that improved throughput.
Shorter duration with earlier slab/deck access.
15% cement/SCM reduction and no wet curing/curing compounds, supporting cost and sustainability goals.