(Silver Award) Crossgate Road, Port Wentworth (Savannah), Ga.
Contractor: A.G. Peltz Group, LLC
Owner/Engineer: Georgia Department of Transportation
The existing section of Crossgate Road in Port Wentworth, Ga., was a two-lane hot mix asphalt (HMA) roadway with weight limit restrictions.
According to GDOT personnel, replacing the existing HMA with 10 in. of Roller Compacted Concrete (RCC) would increase the structural capacity of the roadway, opening its use to heavy truck traffic. This was especially important to GDOT as they expected traffic counts to increase from an ADT of 7,800 in 2013 to 10,500 by 2023.
Placed by A.G. Peltz, this section of roadway was GDOT’s inaugural project for RCC as the riding surface on a state travel lane.
The majority of the main roadway is 24 ft wide. The RCC was placed in a single pass, which required the roadway to be shut down and throughput traffic to be detoured.
To ensure uninterrupted access to businesses along the roadway, the RCC was started in the middle of the project limits, which greatly helped with the traffic routing. In addition, the rapid strength gain of the RCC (3000 PSI within two days) allowed local traffic to utilize the pavement within 48 hours. To meet the ride specifications for this state project, the RCC was diamond ground to achieve greater smoothness.
According to Georgia Ports Authority personnel, there are roughly 325 acres of undeveloped property along the existing roadway. So now, with the improved structural capacity, the RCC roadway will spur industrial and commercial development along the corridor, thereby increasing the local tax base.
The RCC was relatively quick to place, and provided ports authority, the DOT, and road users with an economical, durable, and low maintenance concrete pavement that will carry heavy traffic for years to come.
(Gold Award) Brickhaven Ash Unloading Facility, Moncure, N.C.
Contractor: Andale Construction, Inc.
Owner: Green Meadows, LLC
Engineer: HDR Engineering
A materials supplier to the power industry, Charah, LLC, along with HDR Engineering, contacted Andale Construction to help them with a unique situation. They needed to build a heavy-duty haul road capable of supporting 160,000 lb. off-road haul trucks that would travel the haul road 350 times per day.
That may not seem like a monumental challenge, but the haul road had to be constructed on top of a 60 mil high-density polyethylene liner without inflicting damage. Adding to the complexity were two ramps with a 10 degree incline in and out of the loading area. In addition to the project complexities, the work would have to be done during the winter … and the paving would have to be finished within two weeks.
Andale Construction worked closely with HDR Engineering to come up with the pavement design, as well as a plan to construct the pavement without damaging the liner, and to do so safely and quickly so the roadway could be put into service within days of completion. Andale also was tasked to construct a subway trench for the rail cars before any of the pavement could be installed.
Andale’s solution was to install a 1-ft thick cement treated base on top of the liner.
Cement treated base (CTB) was chosen for the subgrade because it was determined to be the only product that could protect the liner during construction, while also supporting all of the traffic that had to use the area to construct the rest of the project.
Andale installed the majority of the base and then used it to construct the 1,000-ft long by 30-ft wide concrete subway. The subway construction involved 2,000 CY of concrete and 250,000 lbs of steel reinforcement—and was completed in 20 days.
The 1-ft thick, double layer roller compacted concrete was placed simultaneously. On an average day Andale placed 1,500 CY of RCC, and 2,500 CY of CTB. With 250 people working in an area that spanned about five acres, Andale completed the RCC pavement in six paving days between Christmas and the New Year.
In all, Andale logged nearly 100,000 man hours to complete this work in under one month without a single incident. The pavement was put into service within a few days of completion and now supports the client’s operations around the clock, seven days per week.
* ACPA Member.