Association News

VDOT Receives Lifetime Pavement Recognition Award

ACPA presented its Lifetime Pavement Recognition Award to the Virginia Department of Transportation (VDOT) in recognition of a section of Virginia State Route 316. Accepting the award was Mike Davis, P.E., C.C.M., VDOT, Hampton Roads Deputy District Engineer for Construction and Engineering.

With only minimal maintenance, State Route 316 (Greenbush Road) has served the communities of Accomack County, Virginia, for about eight decades.

This exceptional pavement has far exceeded its original design life and exhibits the durability and performance for which concrete pavement specifiers strive.

“This highway is not only an important travel route for local communities but is an excellent example of the longevity that has become one of the greatest values and true hallmarks of concrete pavement,” says Gerald F. Voigt, P.E., ACPA President & CEO.

Awarded selectively since 1994, this special recognition is presented to the agency owner of an in-service concrete pavement that has demonstrated exceptional performance and service to its local community, state and users. (This recognition rotates annually among public market segments: highway, street and airports.)

Divided Highways (Urban) – Silver Award

Silver Award – I-440 from Arkansas River Bridge to 140 , Little Rock Ark.

Contractor: Koss Construction Company*

Owner:  Arkansas Department of Transportation

Engineer: Bridgefarmer & Associates Engineering

Koss Construction Company had the challenge of reconstructing the concrete pavement on a very busy stretch of Interstate 440 on the east side of Little Rock, Ark.  

Facing a tight schedule, tough access and high standards, the team needed to assemble quickly and intentionally to have a shot at a successful project. Using a majority of local subcontractors and suppliers, Koss hit the ground running as soon as temperatures allowed.  They removed the rumble strips by milling and filling with a magnesium-phosphate based patching material.  After the traffic was switched, it was time to remove the old pavement and make ready for new.

The Arkansas Department of Transportation placed a huge emphasis on the time of construction by bidding it with the A+C method. With a daily road user cost set by the owner at $35,000 per day, Koss bid to complete this project in just 294 calendar days. Every minute counted as the team began to remove and replace over 208,000 SY of pavement along 19 lane miles.

Many issues compounded the complexity of this project, but none more than requirement to match the inside lane profile to the existing 27 year-old concrete shoulder that the owner wanted to remain in place. By carefully planning the removal and reconstruction of some of the most off-profile shoulder segments, the constructed pavement lane was able to meet thickness and smoothness requirements.

The concrete mix used on this project was as close to a Performance Engineered Mix as allowed under current ArDOT specifications. The mix was designed to have a low paste volume with low permeability and good air characteristics. FHWA was on site during paving and verified the quality mix through a battery of PEM tests which included super air meter (SAM), Box Test, Surface Resistivity, Rapid Chloride Permeability and Calorimetry.

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* ACPA member.

Divided Highways (Rural) – Silver Award

Silver Award – I-376, Airport to Business 376, Alleghany, PA
Contractor: Golden Triangle Construction*
Owner/ Engineer: PennDOT, District 11

I-376 Airport Expressway is a limited access freeway that serves as the main access for high speed traffic traveling to Pittsburgh International Airport from the Metropolitan Pittsburgh Area. The average daily traffic on this highway is 50,000, but ADT is expected to climb to 70,000 vehicles.

Golden Triangle Construction won the alternate bid for the project, which included full-depth concrete replacement, minor structure improvements of four major bridges, and updates to the guide rail and median, along with some additional construction. The entire project included 20 lane miles of paving over a span of
4.7 miles. The project also included two major interchanges that serve airport cargo companies and other airport vendors, as well as other businesses in the area.

After being awarded the contract, Golden Triangle proposed three innovative cost-saving ideas:

  • Using 12 in.-thick cement soil stabilization in lieu of traditional undercutting methods to stabilize the subgrade;
  • Recycling existing concrete pavement and reusing it for the aggregate subbase vs. purchasing virgin aggregate; and
  • Designing a new maintenance and protection-of-traffic scheme to allow for full 24 ft.-wide paving in lieu of single lane 12 ft. lane paving.

These recommendations allowed for expedited construction, safer access for construction and passenger vehicle traffic and a smoother pavement. In addition to Golden Triangle’s proactive strategies providing a better finished product, they also saved the PennDOT $1.4 million of the approximately $13.4 million allocated for paving.

Another innovation on the project was the pilot of Performance Engineer Mixtures for PennDOT. Applying the use of the formation factor test, box test, Super Air Meter and water/cement ratio calculation using the microwave test, provided feedback to PennDOT and the contractor, and may lead to the use of more PEM mixtures on future projects.
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* ACPA member.

Divided Highways (Rural) – Gold Award

Gold Award – US Highway 20, Woodbury/Ida Counties, Iowa
Contractor: Cedar Valley Corporation*
Owner/Engineer: Iowa Department of Transportation

When Cedar Valley Corporation completed the final segment of paving on U.S. Highway 20 in Woodbury and Ida Counties, it drew to a close the successful completion of an almost $75 million project. The project was the last of six segments built by three different contractors, who upgraded the highway to a four-lane facility, a project that also include 1.7 million SY included work on intersections and adjacent streets.

CVC paved two sections (and more than 1 million SY of paving). The final project involved 551,901 SY of concrete paving, including 43.82 miles of alternate-bid concrete shoulders measuring 4 ft. wide and 6 in. deep. The project also included 19 crossovers and 42 turning lanes. CVC also trimmed more than 629,000 SY of subgrade.

The overall project scope involved six segments and three different paving contractors. Noting the scale, CVC anticipated the demand on local material producers and haulers. During early planning, CVC purchased a material stacker to build stockpiles in the autumn prior to paving, then added two acres to their plant site to accommodate the additional stores of materials. Even with this foresight, material suppliers could not always keep up with demand for the first year paving , so additional sources had to be identified. By the end of the first year paving, CVC had stockpiled almost 30,000 tons of paving aggregate for the following year. This proactive planning enabled CVC to maintain excellent production throughout the project.

CVC also developed another strategy to allow material producers an opportunity to catch up with CVC’s needs during the project. After paving half the mainline, CVC dropped back to complete shoulders, intersections and side roads.

The large scale of this project proved to be no match for CVC crews, who had only one loss-time injury and no recordable vehicle accidents, even with almost 97,000 hours of exposure. CVC also earned 82% of the smoothness bonus and 100% of the thickness and mix design bonus.

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* ACPA member.

Overlays (Airports) – Gold Award

Gold Award – Runway 5-23 Rehabilitation, Grand Strand Airport, North Myrtle Beach, SC

Contractor: Hi-Way Paving, Inc.*

Owner:  Horry County Department of Airports     

Engineer: Holt Consulting Company

The new runway at Grand Strand Airport in North Myrtle Beach features an innovative 7.5 in. unbonded concrete overlay design on top of existing asphalt.  The concrete overlay provided an excellent means of renewing and ultimately increasing the lifespan of one of the oldest runways in South Carolina.

The runway was originally built in the 1940s as the Wampee Flight Strip and was used as auxiliary landing airfield for the Myrtle Beach Army Airfield. From 1956 until 1976, Grand Strand was the only commercial airport servicing all of Myrtle Beach. Following construction of Myrtle Beach International in 1976, Grand Strand has served the North Myrtle community as a busy general aviation airfield.

Making this project even more impressive was Hi-Way Paving’s ability to bring the project to completion under budget despite the fact that the project was hit with Hurricane Michael during the originally planned first week of the project.  A record rainfall occurred in the area during the course of construction, dumping 68.5 in. vs. the average annual rainfall of 46.12 in.

The project involved converting the existing asphalt taxiway into a temporary runway so that the airport could remain functional for 90% of existing traffic during the project. Once the temporary runway was operational, Hi-Way Paving milled the surface of existing asphalt runway to create a uniform 1.5% cross-slope of asphalt as a new base course, and then overlaid the runway with 7.5 in. of concrete pavement using a central mix batch plant.

In addition to the overlay, the contractor was also responsible for milling, widening, and overlaying the 3 existing asphalt taxiways to meet the new runway grades and slope requirements. Finally, the project included the full depth demolition and relocation/realignment of two existing mid-field asphalt taxiways.

The scope of the project, the hurricane and heavy rain proved no match for Hi-Way Paving, which complete major construction work less than a month behind the original planned completion. 

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* ACPA member.

 

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