STATE OF ILLINOIS HIGHWAY COMMISSION BULLETIN NO. 4. Crushed Stone Prepared by Convict Labor and Rules for Its Use. COMMISSION EDMUND J. JAMES, Chairman, JOSEPH A. FULKERSON, LAFAYETTE FUNK. A. N. JOHNSON, State Engineer. Springfield, Illinois, March, 1909. SPRINGFIELD, ILLINOIS: Illinois State Journal Co., State Printers, 1909. STATE OF ILLINOIS HIGHWAY COMMISSION BULLETIN NO. 4. Crushed Stone Prepared by Convict Labor and Rules for Its Use. COMMISSION EDMUND J. JAMES, Chairman, JOSEPH A. FULKERSON, LAFAYETTE FUNK. A. N. JOHNSON, State Engineer. Springfield, Illinois, March, 1909. SPRINGFIELD, ILLINOIS: Illinois State Journal Co., State Printers, 1909. a: Illinois Highway Commission. til NO. 4. PI. 1. 3 • 11 « — O C - ~ Si 4> Si - -r O CS = : u « O ■ a « -3 °«a > = .3 - a A 3 a) o a •oo ■— 4> S3 ■So a - l_ 3 4> 0£ 4) C 4>" = a rH'O.C ■*Sg. §-*°~ U U © O) o -o U 41 a - Crushed Stone Prepared at the Penitentiaries. Law Regarding Convict Labor on Road Material, Etc. An Act to amend section 2 of an Act entitled, "An Act authorizing and em- powering the employment of convicts and prisoners in the penal and re- formatory institutions of the State of Illinois in the manufacture of tile and culvert pipe for road drainage purposes, and in the manufacture of machinery, tools and appliances for the building, maintaining and repair- ing of the wagon roads of the State, and for preparing road building and ballasting material, upon the requisition of the State Highivay Commis- sion,^ approved May IS, 1905, in force July 1, 1905. Section 1. Be it enacted by the People of the State of Illinois, represented in the General Assembly: That section 2 of an Act entitled, "An Act author- izing and empowering the employment of convicts and prisoners in the penal and reformatory institutions of the State of Illinois in the manufacture of tile and culvert pipe for road drainage purposes, and in the manufacture of machinery, tools and appliances for the building, maintaining and repairing of the wagon roads of the State; and for preparing road building and ballast- ing material upon the requisition of the State Highway Commission," ap- proved May 18, 1905, in force July 1, 1905, be and the same is hereby amended so as to read as follows: § 2. The commissioners of highways in any township in counties under township organization or the commissioners of highways or boards of county commissioners in counties not under township organization, may make ap- plication to the said State Highway Commission for such road building ma- terial, tile, culvert pipe, road making machinery, tools and other appliances as may be needed or required by them for the construction, improvement or repairing of the wagon roads in their respective townships or road districts, and where by agreement of the commissioners of highways in counties under township organization, or the commissioners of highways or boards of county commissioners in counties not under township organization, as the case may be, with the city council of any city, or the board of trustees of any village within the limits of such town, any gravel, rock, macadam or other hard road is extended within or through the corporate limits of such city or village then for the construction, improvement or repairing of so much of said road as lies within the corporate limits of such city or village, provided such exten- sion within such city or village shall be of the same cost and kind of ma- terial as the road outside such city or village, obligating themselves to use such material according to the rules and regulations formulated and approved by the State Highway Commission. Approved June 3, 1907. Revised Law Concerning the Use of Free Macadam. The law which provides for the distribution of crushed stone, pre- pared at the penitentiaries has been amended so that this material may be used inside the corporate limits of villages and cities, provided it is used in extending a road from the township into the corporation, and that the township officials give their consent for the material to lie so used. I ONVK 1 LcABOB l'l;i P \i;i - ( 1.1 BHED StONR The employmenl . 1 1 •< >r in preparing crushed stone has far proved satisfactory . Many inquiries ha a received from other states in regard to the details of this plan, which ii is believed is one of the most practical ways of employing convict labor in road construction, [n a number of . more particularly in Borne southern states it has been Ihe prac- tice to \\ <»rk the convicts on the road itself, and especially in North Carolina and Georgia ;i number of miles of road have been buill very successfully in this way. There is, however, in mosl sections of the country a natural ] • r« •- judice againsl exposing convicts on the public roads. It does uol Beem justifiable to place the opportunity for escape bo alluringly before the prisoner and to impose as a penalty on his very natural desire to seiae this opportunity the risk of being shot by armed guards stationed at a considerable distance, as a protection againsl a sudden rush upon them. If a Bufficienl number of guards were provided to render the use of rifles unnecessary, it would be found that the cosi of paying the guards would more than compensate for the reduced cost of the convicl labor, bo thai in the end the work would probably cost m< than if performed with free labor. Another, and perhaps more important, consideration would be the very natural feeling that the Laboring man would have against com- peting with convict labor which, moreover, would bring this class of work into more or less disrepute. But tin- employmenl of the convict- inside the penitentiaries or with- in stockade-, where they are not exposed to public view, and where the methods of guarding and other precautions taken againsl escape are practically tin 1 same ;i~ would be necessary whether the prison were idle or employed, seems, both humane and practical. CTnder tic conditions, there is no additional cosi to the taxpayers at large for the product of their labor, so that whatever is produced by their industry i- bo much gained by the community. Moreover, preparing the crushed stone interferes, in this state, with no existing industry a- the crushed stone i-. in alnio-t every instance, used in places where it would not he tried unless it could he Becnred at the specially low rate- that this method of production Becures. In fact, it. can truly be said that tho State, tather than interfering with an existing industry is in reality creating an industry, for the total amount of crushed -tone, even if all the convicts were employed, would at the ino-i 1 ip very small when com- pared to that which would he necessary should any general scheme of road improvement be undertaken, even in hut a few localit Neither is free'labor in any wise brought into unfair competition; on the contrary, work for free labor is created in constructing the roads, which, in many instances, would nol otherwise be undertaken. There is also another point of view which recommends this method of cooperation from the fad that no locality i- at any increased ex- pense for ihe benefits that certain communities, which secured the crushed -tone prepared in this way. may derive; nor would the ex- •amission. tin S I. PI Illinois Highway Commission Bulletin No. 4, PI. 3. pense to any community be less if no one received the crushed rock, so that it is difficult to see how a more equitable plan of cooperation could be devised. Additional Crushers Needed. There is a great demand for the material, Ear greater than the presenl capacity of the crushers can furnish, and n \yoi in if this work is to be carried on that some means should be devised whereby a '■'•Main number of convicts could be established a1 other places and atone de- pots opened. If such depots are established, two point-; must necessarily be borne in mind: First, that the material is of suitable quality and in sufficient quantity, and second, that transportation facilities are at band. In general, a quarry would be more advantageously bcated if it were possible to ship the stone in the direction of the emptj coal car movement, which would be of considerable advantage in indui the railroads to maintain low freight rates. ■ Rules Governing Distribution of Crushed Stone. l. All applications musl be made on the regular forma furnished by tin S Highway Commission. Bach application for materia] -hall be signed by the local high- way comm re, uh<» thereby thai the material will be irding to the rules and regulations prescribed by the State Highway I as required by law. The State Highway Commission will maintain a general super- vision of all work where material furnished by the commission is used. I. The general method of construction to in- followed has been out- lined and printed. These instructions will be supplemented by the Engineer <<\ such further directions as the special «-< >i t< 1 i t i • ki i individual quire. If it should be found thai the material supplied by the commis- sion i- inn used in accordance with its plans and directions a- mad tin- StMi. • Highway Engineer, further deliven of such material will stop immediately on the order of the State Highwaj Engineer and will nol again be continued under the same application ui by the State Highway Commission. * In .-ill cases where tin' shipmenl of- material has been ~ t < > j » [ n *< 1 through Don-compliance with the regulations of the commission, the authorities may apply anew t" continue tin- shipments, bu1 this application will be taken up in turn with other applications that may be "ii tilf. Before an\ application will be considered by the State Highway Commission the local officials making the application for material must ;j;\\r Buch information concerning the proposed work- on which said materia] is to be used a> will satisfy the commission thai the prop improvemenl will be lot- the benefit of the general public. Tiir State Highwa} Engineer Bhali, before an application \<>v stone i- gran-ted, \i-it the site of the proposed improvement, confer with tin- local highway officials, ami reporl to the State Highway Commission his recommendation in relation to the application in question. 9. No application for less than 1,000 cubic yards <>( -ton.- will considered. 1". No township, or districl (in counties not under township ganization) -hall receive in any twelve consecutive month-, unless other- wise ordered by the commission, more than 3,000 cubic vard tone, Illinois High? HnllPtln No. 4. PL 4. 3 C SZ i . ■5 V. — s B o X g e o ' a) , a ".n a unless no other applications are on file on which shipments can be m and this rule shall apply whether the stone be ordered l>\ township county officials. 11. After the date of the approval of these rules and regulations the State Highway Commission, all applications for stone on file, or subsequently received at the oilier of the commission shall be uumbered consecutively in the order of their receipt; and. so far as practicable, shall be approved and filed in the sam "der. It is, however, under- stood that before any application for free materia] shall be approved, the local authorities making application must give ample evidence of their intention and ability to use said material in accordance with the requirements of the State Highway Commission. 12. It is to be understood that the Stale Eighwaj Commission will give preference to those applications from points at which experimental work is under consideration, and that shipment- to such points may be undertaken irrespective of the date of the application tor the crushed stone. 13. Experimental work is not undertaken by the State Eigway Com- mission unless a special petition for such work lias been filed b\ the local highway commissioners, accompanied by a requesl signed bj at least twelve farmers or busim ss men in the community where the road is to be located. The petition to be signed by the local highway com- missioners must be on the regular blank forme Furnished by the State Highway Commission. 14. Before any shipment is made, the State Eighway Commission will ascertain the freight rate, the lowesl it has been able to secure, and notify the local officials accordingly. 15. Before any shipments are made notice will he given the local officials who may, if they find they cannot receive the stone at the time designated, notify the State Highway Commission to delay shipments. If this is done, no shipment will lie made, but the officials b\ so doing will lose their turn and will have to await such a time before stone will be sent as though their application was of the date shipments were or- dered stopped by them. Instructions for Making Limestone Macadam Roads Without Use of a Steam Roller. Many inquiries have been received as to the method to be f«>l 1« >\% ••« I in placing macadam material on a road. There is Borne difficulty in ■ directions which would cover all The objed has always been, when crushed stone has been furnished by the commis^ Bion from the penitentiaries to have the work 'lone better it" possible than Bimilar work had been done before in a particular Locality. In mosl instances, however, it is the firsl experience of the Local commis- sioners with this class oi work. Also there is usually hut a small amount of monej at hand s<> that the beel methods and beei n are not always obtainable. In hut '.nc or two instances have townships owned rollers bo that all instructions for placing macadam are given, bearing in mind that a roller is not at hand and that the work must he done to the he-t ad- vantage nosaible omitting this very desirable feature. Borne of the direc- tions are -t forcibly impressed by citing a tew "don'ts." Pebpabiki; i hi: K'oad Bed. There is a greal temptation not to give tne proper care to the prep- aration of the road on which the crushed Btone is to he placid and we have frequently to repeat, don't nut crushed Btone on a road until it has been' properly rounded ami graded up ami all hole- and dej - tilled. I ton* t mi depressions or mud holes with crushed stone. Earth i> the proper material to use and it is vrerv much cheaper. The firsl -top therefore is to prepare the road to receive the crushed -tone. This i- quickly done with a road machine or grader operated in Buch a manner that the earth i- thrown < utside rather than to the in- side of the road. This i~ very readily accomplished it' a furrow is first plowed with tin' land Bide toward- the outside of the road. The furrow should outline the edge of the macadam. The blade of the road ma- chine ie thai it throw- ; i -mall ridge of earth to the outside of the . leaving the center portion a- nearly undisturbed a- possible. The width of the road-bed Bhaped in this manner Bhould be about 1<» or 12 feet or tii,. same width that it is proposed to have the macadam. The center of the road Bhould he about -i\ inches higher than at the Bide on ;i l'.' fooi road. It is well to have this part of the work done ,-i- much ahead a- possible o that the traffic can roll the road-bed and i • Commission. Pullet In PI. 5. u. 1 o ^ o o V a. — - u 3 O o u V c . 00 'E 3 1 ~ •~ 03 c o ° Illinois Highway Commission. Bulletin NO. i. i A. How not to spread stone. It costs scarcely any more to keep the edges even and straight. B Do nol ie1 your road gel in this condition. Ruts like u ■ care is taken to rake in loose ston< as often as ruts form. Compare this wltn plates 9B and 10. it especially wherever H has been necessary to till depressions, tf the traffic cuts the road very much, a road grader should be used to Bmooth it immediately before the stone is Bpread. Side Drr< ees. Where the road is through Level country, the Bide ditches should be broad and approximately 30 inches below the center of the finis road. The slope of the side of the ditch towards the road i be about one foot fall to every four feet lmri/.n ntal, and the side of the ditch towards the fence or the outside of the road could have a some- what steeper slope, about one foot to even two feet. Ditches made in this manner do not cave in every spring. It is only necessary to cut the weeds to keep such a ditch in good shape. The shoulders and dit should, if possible, be sown with grass seed or if this is not practic- able see that the weeds are cul early in the season and kepi cul so as not to smother the grass which will eventually come up and form a close sod which is a great protection to the sides of the ditches and the shoulders as well as adding greatly to the appearance of the road. Embankments. Through low swampy places, a satisfactory road can be built only by iirst throwing up a suitable embankment so that the road bed is raised above the general level by at leasl 18 inches and should be high enough so as to be well above all ordinary water that may stand along- side the road. The embankment should be not less than 22 feet wide on top, preferably 25 feet, and should have as gradually sloping s as possible. To build an embankment properly the earth should be spread in layers of not over 12 inches thick and wagons and teams driven over all parts of it so that it will be impacted as much as possible during construction. The earth should be spread at first to the total width that it is necessarj to make the embankment, including the slopes. For example, if the embankment is to be 25 feet wide ; it the top and is to be built 4 feet high and the side slopes are to be two horizontal to one vertical, it is evident that the embankment will tend to each side of the road for eight feet so that the distance from the toe of one slope to the toe of the other will be 1G feet plus 25 Eeet or 41 feet. Very often the embankment is constructed by spreading the earth on the bottom merely for the width that it is desired for the top of the embankment which is built up, and dopes made by dumping the earth over the edge. This will not give as solid an embankment nor one that will hold its shape as well. ( lONSTEUCTION OF SHOULD] The earth which is thrown up at the sides and forms the Bhoulders prevents the stone spreading and the traffic displacing the edge of tin- stone. The shoulders should be formed before the stone is spread. In a number of instances the stone has been placed upon the road with no attempt whatever to form shoulders. This is do! the right way. 10 Z \ b^ 2 < 1 J . Q / 1 fcv /. < / ' t' ~ O s / IssK F MA 1 — ' r ■■' i f . . if:- • it. '■£-■ -*. U. g~ *5 if:. u z |K X 5 5 < «x »• i- -- -J K w > a. Is >- — oc !• w O — L. — b \i\> wn l nder-1 >h u \ ■ The cut >h«»wii in Figure 1 illustrates the various Bteps here de- scribed. As the work progresses, there should be cu1 through the shoulders a1 intervals of about 50 feet, trenches about the width o shovel and to such a depth that the water will run readil) from the road-bed to the side ditch These trenches should be filled with broken -tone or gravel, whichever may be at hand, and aboul the Banie thickness as the layer of stone in the first course. The remainder of the trench is Idled with earth so that these drain- do not -how on the surface of the shoulder. The side drains and Bhoulder drains tend to keep the road-bed dry and also to drain the shoulders and are. in no case, to be omitted. If there is under -round water a- shown by a Beepy or quaky place, it will be uecessarj to run a tile drain through such places and carry it to an outlet in the side ditches. If this is not done, do amount of stone which could be put in such a place will be effective to prevent a mud-hole from eventually forming. In very level country where s • drainage is difficult to secure, it is important to have the center of the road elevated as much as possible so that the foundation of broken stone will at all times be well above the level of the wat< r in the side ditch Figure No. 2— Sketch illustrating position of lateral drains, which should be cut as soon as roadbed is shaped so as to drain water from the ! to the side ditches. 12 Spreading Fibsi < 01 asi oj Stonb. -•nil step is to Bpread the I Btone. I . it ifl planned to put a LO-inch layer on the road, don't put it all on in one layer, h Bhould be pul on in two layers. \- practically all the j-t»n btainable in Illinois is limestone which is but moderately hard, better to reverse the usual order of making a Btone road and put in the firsl or on the bottom <>f the road the l ' L . vat ma- il which should be evenly spread for a thickness of four to five in< A Btrong-toothed rake lb one of the best implements of the road maker. Stone 'thai is Bpread by a rake will be stirred up and the small pieces will take their natural position at the bottom of the layer and tho stone will, therefore, compact \>-r\ much more quickly and the la pieces will not tend to work to the Burface as they will inevitably do if placed nt the bottom. As thej come to the surface the whole ! is disturbed and loosened. \ Btrong toothed harrow i- recommended as an excellent means to Bettle the -tone in place after it has been evenly Bpread. Bach layer of .-ton.- should be harrowed thoroughly. SPRE M'l $Q Si;. OND < lOl BSE 01 STONE. Tile lle\t Step i- to -pl'ead the -ecolid hlVef or top coll' This should consist of the three inch materia] which is evenly Bpread with rake.- as in the case of the lower course of stone. \ word should be Baid about method used to spread -tone. The itial thing i- to gel an even layer of material. This cannot be done it the -tone is raked from a pile as it is dumped upon the road center of a pile of stone i- always more compact than the ma- terial that i- raked to the edges. It is therefore, necessary that all the stone is rehandled. A \<'i-y convenient way to measure the thickness to which the -tone i- Bpread i- by blocks of wood. It the material i- to he Bpread •"> inches thick, then the blocks Bhould he cut to measure •"» indie- in all di- mensions -o thai no matter which way the block may lie Bet, it will he li\e inches high. At Least twelve of these blocks should he made. They should he set three in a row upon the roadbed, one in the center ami one "u either Bide. Three more Bhould be placed aero— the mad- Led in a similar position about -i\ or eight feet from the iir.-t row. As soon a- the -t i- spread around the first row of blocks, they are taken out and Bel ahead ami the pri repeated. There Bhould he a similar set of blocks for each layer of -tone. A- before uoted, the road-bed should he shaped true enough so a- not to require more -ton'' in one place than in another to -eciire an even Burface. Stone cannot be Bpread "by eye." When it i- home in mind that a variation of imi one inch in thickness means ".' II ton- per mil* road. 12 feet wide, the importance of using only so much material a- i- necessary t- evident. Illinois Highway Commission BnllPtln No. 4. PI. 8. 3 O JB en n\ in the construction of the upper course. Instructions fob Placing Gravel. Gravel roads should be built in much the same manner as already outlined for building macadam roads. Particular attention should be paid to thoroughly spreading and raking the gravel so that the finer parts are sifted to the bottom leaving a layer of the larger pebbles and pieces of stone on the top to form a wearing surface. There are many cases where the grave] is found very close at hand but of such sandy nature that it will not form a good road surface. Such gravel can. however, be used to advantage at the bottom of the road which could then be covered with a four or five inch layer of crushed Btone. In this way the crushed stone would go very much further than if the road was huilt entirely of stone. A small amount of fine gravel makes a good binder for a layer of limestone, in fact it ha- been found to give a better ! d than is obtained with limestone screenings alone. The usual method of dumping one Load of gravel at the side of another and Leaving the traffic to Bpread and c pad it cause- far too much inconvenience to traffic and Bhould not be permitted. The question is frequently raised whether macadam or gravel should lie Bpread in the center of the road or at one side, having an earth road on one side and -ravel on the other. The besl practice is to place the macadam or gravel in the center and. if there is sufficient room, a side 14 id tan be made the road as to the hoi and grounds alongside it. A beautiful road-side attracts people and enhances the value of the property in the neighborhood. The first 1 1 1 i 1 1 lt t<> be encouraged is the growth of a good Bod from th< of the traveled way t<> the fence line. Keep the weeds « ut and give tli- a chance to grow. Where there are no trees, them out. There is an opinion in the mini!- of many that trees harm a road, claiming that they retail] Hie moisture and arc in other w. baneful. Wherever the road ia bad in the neighborh 1 of trees, the trouble is not with the trees but with the road. If the road were |>r<>|>- erly constructed and drained, the trees would cause n<> further trouble In fact, with a macadani road, the moisture thai would be held in the Burface in the summer time would be a distinct advantage. In the winter time, if the low-hanging limbs are trimmed, there will be |>r.. tiealK as much Bun and wind come upon the road as though there were ii'< trees, while their value in the summer time cannot be over stated. the road Bide should noi be cut down at the caprice of an individual commissioner or even ol the land owner alongside. Ti are a public asset and Bhould be most jealously guarded and cut only after due consideration l>y public officials who Bhould be chosen for thi> purpose, or have these duties imposed upon existing public officials, but in any event, prevent the wanton destruction of beautiful shade n mi the road Bide, (are for the trees you have, set out new ones; it pa • - W.9 0. Illinois Highway Commission. Bulletin N • i. 1-1. in.