Association News

Municipal Streets & Intersections (>30K) – Gold Award

Gold Award – Meridian Boulevard Phase 1

Contractor: Castle Rock Construction Company*

Owner/ Engineer: Douglas County Public Works

Meridian Boulevard in Douglas County, Colo., was built in the early 1980s with a design life of 20 years. After nearly 40 years of service, the road was exhibiting materials-related distress and scheduled for reconstruction.

The section scheduled for reconstruction is directly in front of Dish Network Corporation’s headquarters office, a location that has over 2,000 cars entering and leaving the facility each weekday. In addition to high traffic volume at the construction site, tight space constraints, and requirements to protect existing landscaping, a 90 calendar-day schedule added to the complexity of the project.

A significant amount of subgrade restoration was required in the 0.71-mile project designed to expand the road to four lanes. Soft spots were removed and replaced with recycled concrete road base. 30,100 SY of concrete were placed to complete the 3.51 lane mile project.

Environmentally friendly strategies employed in the project included:

  • The cement was a 10% limestone replacement which lowers the release of carbon monoxide from cement production by 10%, which lowers the carbon footprint; 
  • Use of fly ash, an industrial by-product from coal burning power plants, was used to stabilize the concrete; and
  • Concrete from the original road was crushed and used as road base for the new pavement.

In spite of an early season snow, traffic volume and measures to protect existing landscaping, the project was completed 20 days ahead of schedule and will provide DISH Network employees, visitors and area travelers with a long-lasting roadway capable of handling the rigors of traffic, while also factoring in important environmental considerations.

* ACPA member.

Municipal Streets & Intersections (>30K) – Silver Award

Silver Award – KY 9 Connector-Roundabouts, Newport, KY

Contractor: Prus Construction*

Owner:  Kentucky Transportation Cabinet             

Engineer: Gresham Smith, Inc.

The construction of the 1.4 mile KY 9 Connector was not just about moving traffic smoothly through the area. The project was essential to economic development in an area where investment was stifled because of high traffic volumes and traffic congestion through residential neighborhoods.

Boasting the first two concrete roundabouts in Kentucky, the project was designed to mitigate the usual stop and start traffic snarls in a busy area. The connector is 10 in. jointed plain concrete with 23 ft. joint spacing.  The main roundabout has a 125-ft radius and is a 40-ft-wide roadway for two lanes of traffic, and the second roundabout has a 105-ft radius with a 40-ft-wide roadway and two lanes of traffic. A total of 42,000 SY of concrete was used in the project.

In addition to the connector and two roundabouts, the project also included concrete sidewalks and bicycle lanes to improve safety for pedestrians and bicyclists. Commuters no longer have to wind through neighborhood streets with a multitude of traffic lights and turns to reach Newport and Newport on the Levee, a large entertainment venue.

Shortly after this project was completed, a $1.5 billion dollar development was announced on a 35-acre site in the area.  The project will be built on a site that been vacant for 13 years.  The new connector, roundabouts and sidewalks not only keeps traffic moving, but also symbolize the vitality and economic hope for this area.

* ACPA member.

County Roads – Gold Award

Gold Award – County Road 47, Weld County, Colo.

Contractor: Interstate Highway Construction*

Owner/ Engineer: Weld County Division of Engineering   

Reconstruction of Weld County Road 47 was the third and final phase in completion of the County’s Weld County Road 49 Corridor, providing a north-south alternate to 1-25 and US 85, the largest project designed completely in-house by the County.

County Road 47 from County Road 60.5 to State Highway 392 was an existing two-lane, 3.5-mile rural asphalt road with ditches on both sides. Now, the roadway includes four lanes, a continuous 16 ft. general purpose lane, acceleration and deceleration lanes at intersections, a median guardrail and a new irrigation system critical to farmers. More than 167,000 SY of concrete was used to pave 12.89 lane miles at a paving cost of $6.3 million in a project that cost a total of $21.2 million.

The project used a geogrid to mechanically stabilize the subgrade in lieu of the typically specified R-40 subgrade. A new fusion bonded epoxy that fully encapsulates dowel bars was used to provide steel corrosion resistance said to be on par with stainless steel bars. A cure/sealer was used on the concrete to promote sulfate resistance. All concrete aggregates were mined on-site, not only to meet the project demand, but also allow for the continual optimization of the mix design. A non-destructive pavement thickness system was used to determine the concrete thickness without coring into the concrete, thus reducing future maintenance issues.

Public traffic was detoured which allowed for the road to be completely closed for construction – providing a safe construction zone, while expediting the project schedule. Thanks to the hard work and innovative solutions used in this project, this section of County Road 47 reopened five months ahead of schedule.

* ACPA member.

County Roads – Silver Award

Silver Award – County Road T-26 Marble Rock, Floyd County, IA

Contractor: Cedar Valley Corporation*

Owner/Engineer: Floyd County, Iowa     

A challenging work schedule under any circumstances can make pavement construction challenging, by when Cedar Valley Corporation discovered about 41% of a 6.05 mile reconstruction project area required substantial subgrade repair, crews responded with creative solutions based on expert decision-making, hard work and the use of maturity testing to get the job done.

The Iowa County Road T-26 project involved removal and recycling of the existing 9 in.-thick asphalt (which was milled and hauled to an asphalt plant).  Tackling the subgrade issues, crews removed 17,893 CY of unsuitable material, then placed about 32,000 SY of geogrid fabric and 34,000 tons of rock. The excavation for the base rock was successfully incorporated into project by widening the proposed shoulders. This eliminated the need to haul material off the project, thus providing fuel savings and also eliminating a potential fugitive dust situation.

The geogrid fabric and rock created an ideal platform on which the contractor then placed 78,662 SY of 8-in. concrete pavement.  The new roadway was designed to be paved 22 ft. wide with 5-ft. rock shoulders. Based on the narrow shoulders, CVC chose to place the concrete directly in front of the paving operation by trimming and placing the concrete with one machine. CVC pressed into service an “Iowa Special,” a modified CMI dual-lane trimmer configured with a dumping belt placed over the machine.  The machine allowed the crew enough space to set and place dowel baskets directly on the freshly-trimmed grade and just ahead of the paver.

Although the actual project was closed to through traffic, local access had to be maintained, an especially important point as the construction was done during Iowa’s peak harvest season. CVC not only maintained access to 17 residences that lined the road, they also had to provide access to 40 field driveways for local farms. Excellent communication with property owners (advance stockpiling of driveway materials at each property) and the use of maturity testing enabled CVC to balance local access with the need to ensure the pavement was not damaged because of opening too early.

In spite of completing about $628,000 in extra work, DVC successfully completed the project within the 100-day schedule, creating a durable road that will last for many years.

* ACPA member.

Concrete Pavement Restoration – Silver Award

Silver Award – Taxiways F & G Rehabilitation Project at Denver International Airport

Contractor: Interstate Highway Construction, Inc.*

Owner: City and County of Denver, Department of Aviation

Engineer: Jviation

Located on the west side of Denver International Airport (DIA) Concourses, Taxiways F and G provide access to all the westside runways. The taxiways are heavily used by aircraft at all times of the year, but during winter months, they also provide access to critical deicing pads. Because of the importance of these taxiways, close attention to detail and quality construction were extremely important considerations.

The project scope removal and replacement of about 22,000 SY of 17 in. and 21 in.-thick concrete panels, repair of 123,000 linear feet of joint seals, and electrical system renovation.  The project required grading and drainage upgrades to comply with FAA criteria, repair and adjustment of utility structures, and 13 acres of seed and mulch. The total project cost was about $10.7 million, with the pavement amounting to about $5.3 million.

Interstate Highway Construction had a total of nine milestones, five major phases with additional sub-phases for the pavement construction and restoration.  The contractor met or exceeded the milestones, in spite of challenges posed by the staging phase and sub-phase.  For example, some subsections were located in the middle of others, so IHC had to complete some sections out of order—and had to begin some sections at the same time—to meet the milestones.  With the risk of liquidated damages of $75,000 and $25,000/day, IHC’s hard work and attention detail enabled crews to finish all the work within on time and some sections ahead of schedule. 

The project required a 100% quality control inspection with random quality assurance inspections, and because of the close communication and cooperation between the owner’s representatives, both quality and safety were hallmarks of the project.

* ACPA member.

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