Association News

Concrete Pavement Restoration (GOLD)

I-40 CPR Express Design-Build Project, Winston-Salem, NC
Contractor: The Lane Construction Corporation
Owner: North Carolina Department of Transportation
Engineer: Progressive Design Group, Inc.

The goal of this project was to improve the cloverleaf interchange of I-40 and US52 to handle expected traffic volume increases from a two-year shutdown of Business 40. The project involved removing and replacing existing damaged jointed concrete slabs and placing new, jointed concrete pavement.

Facing a requirement to remove and replace significant amount of concrete pavement a single construction season, would have been challenging enough, but The Lane Construction Company also faced many other factors, including:

  • Managing restrictions that limited lane narrowing or lane closures between 5 a.m. to 7 p.m. (Monday thru Friday).
  • Completing undercuts that were required ahead of placing new concrete pavement, all within the same shift during the week or within the same weekend closure.
  • Encountering continuously reinforced concrete or extra depth concrete that required modification of concrete removal methods.
  • Contending with reduced work areas and night work.
  • Managing high-volume, high-speed traffic on both I-40 and US52.
  • Managing the project around event-related restrictions, which included all holidays, Wake Forest football home games, the 10-day long Dixie Classic Fair restrictions (which extended from 6 a.m. to 9 p.m.), Bowman Gray Stadium Racing events, and Winston-Salem State football games.
  • Coordinating with surrounding projects and manage resources using a non-conventional work schedule.

Because of lane closure restrictions, the contractor used a very high early-strength concrete mixture to achieve the 400 psi flexural strength requirement prior to opening to traffic. Lane Construction used a combination of volumetric rapid set concrete during nightly closures and an accelerated, 12 hour/24 hour ready-mixed concrete when extended closures were permitted.

Equally important was a thorough work plan Lane Construction developed to meet the many challenges, while also maintaining productivity and quality. One factor that could have impacted quality was the risk of damage to recently placed concrete while removing concrete from adjacent areas. To protect the new concrete, expansion material was placed between the new and existing concrete pavement intended to be removed. Despite significant challenges, this exceptional project was delivered on time.

Concrete Pavement Restoration (SILVER)

US 160/US 550 Concrete Pavement Rehabilitation
Contractor:  ACME Concrete Paving, Inc.   
Owner:  Colorado DOT
Engineer:  Colorado DOT, Region 5 Durango Residency

The Colorado DOT used a cost-effective strategy to rehabilitate a busy highway, and despite challenges, was able to complete the project ahead of a very busy tourism season. 

The project involved work on the concrete surface and shoulder on a 27-year-old section of US Highway 160/660 through the City of Durango.  The $6 million project had a few challenges, including two change orders that pushed the project completion date out two months. The project involved adding ADA ramps to 15 corners, unexpected bridge deck rehab, and additional manhole and valve-box adjustments.

The contractor also diamond-ground close to 150,600 SY of pavement and completed joint/crack resealing on existing pavement.

Overall, the contractor improved the roadway smoothness, restored skid resistance, prolonged the life of the original pavement, and enhanced the safety of the highway. In addition to replacing and patching damaged concrete pavement, the contractor also removed conflicting stripe shadows, installed new pavement markings with bike lanes, and installed bike friendly inlet gates.  

One of the greatest benefits of the project was that it was a more cost-efficient alternative to an estimated $40 million to $60 million that complete reconstruction would have cost. Concrete batching was allowed only during daytime hours because of local ordinances, but ACME Concrete Paving was allowed to work day and night for six days per week to complete the work on time. This schedule also allowed the contractor to avoid the local lane closure restriction, which in turn, allowed crews to work large sections with minimal traffic impact.

As a result of the efforts of the project team, the business owners, residents, and traveler in this area have are now driving on a 27-year-old pavement that has now has an additional 15 to 20 years of life added to it.

ACPA Names 29th Annual Excellence Awards

It’s official!  ACPA has named the recipients of the 29th annual “Excellence in Concrete Pavement” silver and gold Awards. Please follow the links below to read more details and to view/download photos!

 

Reliever & General Aviation Airports (GOLD)

Sioux Falls Regional Airport 2017 Reconstruction
Contractor:         T&R Contracting, Inc.
Owner:                 Sioux Falls Regional Airport
Engineer:             KLJ 

Carefully planned and executed construction staging is important for any airport project, but it was particularly important considering the scale of the reconstruction and rehabilitation project at Sioux Falls Regional Airport, which is home to the South Dakota Air National Guard’s F-16, “Fighting Falcon” jets. 

The project consisted of the partial reconstruction of runway 3/21; partial reconstruction of taxiways A, B4, and B5; rehabilitation of taxiway K rehabilitation; reconstruction of the aircraft arresting system on runway 3/21; and the partial reconstruction of National Guard Drive.

The project consisted of the partial reconstruction of runway 3/21; partial reconstruction of taxiways A, B4, and B5; rehabilitation of taxiway K rehabilitation; reconstruction of the aircraft arresting system on runway 3/21; and the partial reconstruction of National Guard Drive.

The first phase consisted of the reconstruction of taxiways K and B5, as well as the demo, a 3.5 ft subgrade cut, and placing gravel for 800 feet for runway 3/21 and taxiway B4. The two taxiways had to be completed before T&R Contracting could close the rest of the runway and taxiway A to allow for planes to taxi on K and B5.

The second phase consisted of the remaining demo, grading and placing gravel for runway 3-21, along with work on taxiway A. This work included removing 30-in. thick asphalt and a 3.5 ft subgrade cut, placing a 17-in. thick concrete paving on runway 3/21 and taxiway A, and adding 30 ft.-wide asphalt shoulders. All this work had to be completed in 70 calendar days.

Both phases included a four-step installation of lights, which involved pouring a base and paving over it, adding a 14 in. diameter core, adding an upper section, and then epoxying. In all, there were 128 in-pavement lights that had to be sequenced appropriately to allow room for the paver track and access by the concrete trucks to the paver.

After paving the runway, a 5 ft x 150 x 17 in.-thick section of new paving had to be sawed out for the construction of the Aircraft Arresting System, which serves as the emergency braking system for the F-16 jets.

Another notable detail about the project was the contractor demonstrated a commitment to sustainable construction by in situ recycling of the existing 15-in. concrete paving and reuse of the material for the 13-in. base.

The scope of the project, the schedule, and the other challenges proved to be no match for the contractor, which counted this project as the latest in their on-time, successful projects delivered for the airport in recent years.

Reliever & General Aviation Airports (SILVER)

Lee’s Summit Municipal Airport, Lee’s Summit, Missouri
Contractor: Emery Sapp & Sons, Inc.
Owner: City of Lee’s Summit
Engineer: Crawford, Murphy & Tilly

This is a story about the reconstruction of Lee’s Summit Municipal Airport, but it’s also about much more. It’s about the importance of the airport to travelers and existing businesses, as well the airport’s value in attracting and retaining news businesses.

The project consisted of the complete reconstruction and extension of runway 18/36 from 4,200 linear ft to 5,501 linear ft, as well as the extension of runway 11/29 from 3,800 linear ft to 4,000 linear ft. In addition to increasing the overall runway length, the airport also elected to replace airfield lighting as well as increase the pavement thickness from 6 in. to 9 in., which increased capacity from a 30,000 lb. rating to a 60,000 lb. rating.

The contractor, Emery Sapp & Sons was scheduled to start this work at the beginning of April, but spring rains delayed the start. When the contractor was cleared to start, the crews worked around the clock to meet the aggressive completion timeline. Even though the rains persisted, the contractor still opened the runway within the 21-day requirement.

The second was the construction of the North and South portions of Runway 18/36 which was to be completed within a 182-day closure of Runway 18/36. The contractor completed the second phase in under 70 days, which allowed ample time for all remaining work to be completed prior to reopening the
runway.

In all, the contractor paved 72,375 SY of concrete paving for a total project length of just over a mile or the equivalent of about 4 lane miles, and now the City and the region can boast of an airport that can meet the current and long-term needs of travelers and businesses alike. 

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