We tackled the most challenging job to date with Astec and Roadtec equipment that performed as designed.

The R.J. Noble Company, a leader in the Southern California Asphalt Industry, started out as a small, family owned company. In the beginning, the company had only a rock plant, a small asphalt plant, and a pit mining operation. Today, more than 65 years later, R.J. Noble Company is a Class A, general engineering contractor, delivering excellence in quality, service, and safety.


For the 91 FWY Toll Lanes project, R.J. Noble Company chose to use 3-4 in (7.62-10.16 cm) Superpave warm-mix asphalt (WMA) created at its Orange facility, featuring its 500 TPH (453 MTPH) Astec Double Barrel® plant with warm mix system. The mix contained 25 percent RAP (reclaimed asphalt pavement). Over the course of eight, 56-hour-long weekends, the company managed to remove and replace more than 100,000 tons (90,718 tonnes) of asphalt, finishing the project two weeks early. 

RJ Noble paving the 91 FWY at night

Over eight, 56-hour-long weekends, the company managed to remove the asphalt.
Over the course of eight, 56-hour-long weekends, the company managed to remove the asphalt using Roadtec milling machines.

General superintendent, Chuck Spiers, along with Terry McGill, general manager of operations, were the two point-men on this project. Friday nights kicked off the weekend-work, beginning with the daily safety tailgate meetings for everyone on the job. After each meeting, the grind consisted of:

  • Preparing the Astec Double Barrel® plant at the Orange facility for mix creation
  • Shutting down three lanes of traffic
  • Removing existing roadway with the help of Roadtec milling machines
  • Shipping the grindings to R.J. Noble Company’s Orange facility
  • Shutting down the asphalt plant midday on Sunday, after the final load of material

One major concern for R.J. Noble Company during this—and all—projects was safety of both employees and commuters. In addition to the daily tailgate meetings, McGill explains that Spiers and the crew “had extra CHP (California Highway Patrol) out there to help. There was more traffic control than usual on that job.” For a traffic-heavy roadway, it’s no surprise that a few extra precautions were taken. 


Each weekend over the eight-week project, McGill and his crew would remove nearly 700 loads of RAP and replace it with 700 loads of WMA. McGill noted, “All the material removed from the toll lanes will be recycled and reused in new asphalt products we manufacture.”


Another of R.J. Noble Company’s main concerns is environmental sustainability. “The Orange Plant is one of the few asphalt plants in Southern California to have a South Coast Air Quality Management District approved ACEMS System,” according to the company. “This system and method of continual emission monitoring helps keep our environment clean.” Utilizing its Astec asphalt plant in Orange didn’t just help save the company time and money, it decreased damage on the surrounding community. McGill shared, “The Orange plant ran for roughly 34 continuous hours processing more than 400 TPH (363 MTPH) of WMA at 265 degrees F (129 degrees C); we had more than a 20-percent reduction in natural gas consumption.”

Spiers concluded, “Our relationship with Roadtec and Astec has been good and extremely productive, and we look forward to more rewarding and successful projects.”