Industry News

Municipal Streets & Intersections (<30,000 SY) 

(Silver Award)   Diagonal Highway Reconstruction, Boulder, Colorado

Contractor:  Castle Rock Construction Company 

Owner:    City of Boulder (Public Works Dept.)

Engineer:  Loris and Associates                 

The City of Boulder Transportation Department collaborated with CDOT on this local agency project to design an impressive new “Gateway” into Boulder. This section of SH 119, also called the Diagonal Highway, used to be on the outskirts of the city, but has become a very busy area with what was a deteriorated asphalt road and no pedestrian or bike facilities.

Castle Rock Construction managed and built a complex project with an extensive new drainage system, off-street bike lanes, multi-use path, improved transit facilities, various colored concrete aesthetic components, durable concrete roadway, landscape features and art plazas for the community to enjoy.

The project also involved coordination with multiple departments within the City of Boulder, as well as the Colorado DOT, Regional Transportation District, contractors on adjacent projects, and 20 subcontractors onsite.

In addition to the placement of 27,973 SY of 8.5 in. dowelled concrete pavement for the roadway, the project also involved 31,000 SY of full depth reclamation of the existing roadway, which was recycled into road base for the new concrete paving. 

Some 11,600 SY of asphalt and concrete pavement were removed; 14,000 CY of embankment material was moved; and 10,700 SY of flatwork was completed, including a cycle track, multi-use path, sidewalk, exposed aggregate, colored sidewalk and colored median curb skirt.  The project also involved the construction of rain gardens, which not only added a touch of nature and beauty, but also serve to filter rain and storm water runoff.   The project also included monument foundations and drainage systems for art features.

To accommodate the public during construction, lane closures occurred only during off-peak times throughout the week; bike routes were maintained at all times; and intersection reconstruction work was limited to weekends.

The Diagonal Reconstruction project is the culmination of work by talented contractors whose efforts will benefit Boulder residents and visitors for many years. 

 

(Gold Award)  State Highway 42, Sister Bay, Wis.

Contractor:  Vinton Construction Company          

Owner:  Wisconsin Department of Transportation | Village of Sister Bay

Engineer: REI Engineering, Inc.| Village of Sister Bay

Winding through the northern half of Wisconsin’s famed Door County and along the shores of Green Bay, the state’s WIS 42 corridor is predominantly a two-lane highway connecting many communities where tourism is key.  

The corridor serves as both a ‘travel through’ roadway and a ‘main street’ to these communities, where both functionality and aesthetics are equally important.

Many of the businesses along the project make their living in only a few months of the year, so when reconstruction of a section of this important highway was needed in the Village of Sister Bay, the project requirements were carefully balanced with the needs of businesses and people in the area.

In consideration of the business community, the importance of tourism, and the seasonal population influx, construction was split into eight separate stages.

Vinton Construction proposed a Cost Reduction Incentive (CRI), allowing for placement of high early strength permanent concrete pavement in lieu of temporary asphalt early in the project.  Paving the 1.54 lane mile project with 20,389 SY of 8 in. concrete was completed 163 days ahead of schedule.  In addition to this major accomplishment, the construction cost was $173,000 under the contractor’s bid amount.

The project focused on safety enhancements, protection of the environment, minimizing future maintenance needs, and minimizing the disturbance to the local economy and tourism industry.

Public outreach was a priority to keep the local public officials and businesses informed of the progress.   This included weekly updates; public informational meetings; and day to day communication with local business owners.

Collaboration among the entire project team was exceptional, and included the efforts by the contractor, the engineer, and Wisconsin DOT.  Other hallmarks of the project included excellent design, planning and overall coordination with Village of Sister Bay staff and local businesses; 18 different contractors that were extremely attentive to their work and sensitive to the local businesses; and a Village Administrator who listened to and worked closely with the construction team and made timely decisions; and a construction engineering staff that understood and managed the intricacies and demands of this urban reconstruction project.

 

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* ACPA Member.

2017 Municipal Streets & Intersections (>30,000 SY) Awards

(Silver Award) State Route Rehabilitation Project, Curry County, N.M.

Contractor:  K. Barnett & Sons, Inc.         

Owner: New Mexico Department of Transportation        

Engineer:  CH2M Hill                     

This $2.54M project consisted of new underground storm drain, lime stabilized sub-grade, 8 in. base course material, 10 in. concrete, curb & gutter, and sidewalk.  The project involved 7.5 lane miles along a 1.5 mile-long section of highway in Clovis, N.M.

There were a total of 420 contract days for the project, but K. Barnett & Sons* completed the project in 243. The four lanes of traffic were condensed to two lanes, with two way traffic flowing during construction. 

Some 52 businesses along the route were opened and allowed access during construction, and to help with outreach and communications, the contractor sent letters informing business owners and managers ahead of the project.

Most of the work was completed during the span of time from 7:00 p.m. to 7:00 a.m. to take advantage of higher humidity, lower temperatures, and less traffic.

An average of 3,500 vehicles including semi trucks and pedestrian vehicles passed through the construction site daily.   In spite of the challenges of paving under traffic, limiting paving to night hours, and dealing with a significant amount of traffic and dozens of businesses in the area, the contractor finished the work ahead of schedule and produced a quality pavement that will serve the area for many years.

 

(Gold Award)     I-49 & Peculiar Way Interchange Improvements, Peculiar, Mo.

Contractor:  Emery Sapp & Sons, Inc.      

Owner: Missouri Department of Transportation

Engineer: George Butler Associates, Inc.

The I-49 Interchange with Peculiar Way is in growing area of Cass County, Mo.  The City of Peculiar and the Missouri DOT partnered to fund the new interchange that has allowed the community to have improved access to schools from Interstate 49 and west of the highway.

This Diverging Diamond Interchange (DDI) allows traffic to cross from the right side of the road to the left side at two signalized intersections on either side of the interchange.  These crossovers allow for free flowing right turns in advance of the cross-overs, and free flowing left-turns between the cross-overs. The design enhances the safety and capacity of the interchange.

Additionally, Peculiar Way was extended from School Road through the interchange to Peculiar Drive, thereby creating new access to the northern region of Peculiar.

The project involved more than 130,000 CY of excavation; 4300 feet of storm sewer; a new overpass; two signalized intersections; 6500 SY of sidewalk and median islands; 17,000 feet of curb & gutter; and more than 50,000 SY of concrete paving.

The DDI was completed with minimal impact to travelers and is one of the few such interchanges in Missouri to feature all-concrete construction.  The only stringline set up on the job was for the auto-widener on the paver, which paved lanes that varied from 12 ft to 16 ft wide through the DDI.  

This $9.4 million project took 13 months to complete, and when it was complete, the community praised the contractor for opening the fully-functional Interchange more than two months early. The new interchange has greatly improved access, and is expected to open the region to more economic development.

 

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* ACPA Member.

 

2017 Concrete Pavement Restoration (CPR) Awards

(Silver Award)   Douglas County Concrete Pavement Preservation Program, Highlands Ranch, Colo.

Contractors:  Villalobos Concrete Company* | Chato’s Concrete, LLC* | Interstate Improvement, Inc.*

Owner/Engineer:  Douglas County, Colo.

When the 22,000-acre, master-planned community of Highlands Ranch, Colo., was founded in 1981, arterial roads throughout the community were paved with concrete, with most of the pavement placed directly on clay subgrade.

As the roads reached the end of their expected life, Douglas County officials looked for a cost-effective solution to repair the roads that had a range of problems – broken and shifted panels, joint separation, transverse joint faulting and cracking.

After an assessment of the roads, county engineers determined that a variety of factors contributed to the movement that was causing the panels to break, separate and crack. The 7.5-inch thick pavement was originally built when the volume of traffic and speeds were lower, and the pavement was built without dowel bars to transfer the loads.

Grinding alone could not address all of the issues, so the contracts for the pavement preservation included repair or replacement of panels as needed, as well as resealing joints. The contractual grinding specs were to meet a Half-car Roughness Index (HRI) specification of less than or equal to 150 in. per mile at a maximum grind depth of 0.5 in.

If the concrete pavement smoothness could not meet this specification, then the contractor had to meet a HRI percent improvement of 50 percent or greater per segment per travel lane. If the pavement already had an HRI of less than or equal to 150 inches per mile, the contractor had to meet an HRI of less than or equal to 80 inches per mile without exceeding the 0.5 in. maximum grind depth.

Lessons learned in the first year of the four-year project were applied to subsequent years to address resident concerns, including phasing of lane closures, noise management, and communication with neighboring residents and businesses.

The four-year program included multiple contracts and contractors, and in all, resulted in the improvement of 155 lane-miles of concrete pavement.   The pavement grinding was the largest concrete pavement such effort to date in Colorado. As a result of this project, the pavement life is expected to be extended by up to 20 years.  The project also has provided the community with a much smoother road, increased skid resistance, and a quieter pavements.

 

(Gold Award) State Highway 52 CPR Project, Winneshiek County, Iowa

Contractors:  Wicks Construction Inc. | Iowa Civil Contracting, Inc.

Owner:    Iowa Department of Transportation      

Engineer:   WHKS & Co.

The majestic hills of Northeast Iowa are a phenomenally beautiful attraction for the region’s tourists, especially in the fall of the year.  The problems of a distressed highway running through this area can detract from the beautiful landscape and wreak havoc with visitors and residents.   Not only is the pavement smoothness and noise an issue, but another challenge is how to solve those issues with the least possible impact on traffic.

This was the problem the Iowa DOT faced near Decorah, Iowa, and the owner addressed the issues with an effective patch and grind project that also included partial-depth repairs, full-depth repairs, shoulder retrofits, dowel bar retrofit, diamond grinding, and joint resealing.

The prime contractor, a joint venture between Wicks Construction* and Iowa Civil Contracting, was up to the task, even when the scope of the work increased after letting.

After the project was under contract, the Iowa DOT and Wicks Construction/Iowa Civil Contracting discovered additional pavement restoration would be needed.  This resulted in about 50 change orders, which added $2.5M to the original $6.2M contract. Full-depth patching figures doubled and partial-depth repairs increased almost 13 times the original square yardage.

Along with the challenge of increased work, the project still needed to be completed under traffic. Direct detour routes would have been impractical, because the estimated out-of-distance travel for a detour would have added 20 miles to a motorist’s trip.

Fortunately, CPR with diamond grinding expedited project completion and opening to traffic in the shortest possible time.  Now, tourists and residents not only have a scenic area to enjoy—they also can do so while traveling on a roadway that is in good condition, and features low noise, adequate friction, and a smooth ride.

 

 

 

 

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* ACPA Member.

2017 Roller Compacted Concrete (Special Application) Awards

(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.

 

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* ACPA Member.

2017 Industrial Paving Award

(Gold Award)  Circle Test Track Reconstruction at GM’s Milford Proving Ground, Mich.

Contractor:   Ajax Paving Industries, Inc.

Owner:  General Motors

Engineer:  PEA, Inc.                       

 

In 1924, General Motors (GM) original Milford Proving Grounds (MPG) started with only 1,125 acres of land with 7 miles of tests roads. 

In November 1963, the MPG opened a Circle Test Track, which had an expected service life of 30 to 50 years.  By 1964 the grounds grew to 4,011 acres of land with 73 miles of roads that included the test track. Today the track is busiest and most important test track at MPG. It is used for both development and durability testing of approximately 900 vehicles per year, during which time an estimated 1.5 million miles are test driven.

The original track consists of an upper concrete shoulder, five concrete driving lanes posted for speeds up to 100 mph, and inner asphalt shoulders.  The upper driving lane has a 30 percent bank angle. The parabolic banking track measures about 4.5 miles long. MPG lays claim to the only concrete circle parabolic test track.

A reconstruction project performed by Ajax Paving Industries, Inc.* included: patching of lane 5; removal and replacement of four concrete driving lanes and an inner asphalt shoulder, milling and replacement of asphalt ramps to the test track, resealing existing joints in upper shoulder and lane 5; installation of edge drain outside of the inner shoulder; subgrade improvements; and improved signing, electrical and striping

The 8 in. thick pavement design included the latest Michigan DOT special provisions for high performance concrete and quality control for concrete.  GM required a dolomite aggregate used in the original mix to be used in new high performance mix. The transverse and longitudinal joints were modified to be coated with an enhanced epoxy. GM used the original 20 ft transverse contraction joint spacing, however the design required four transverse expansion joints to be placed at equal distance around the track.

The latest technology was also incorporated into the means and methods of paving. Numerous hours were spent with and by the paving equipment manufacturer to make modifications to paving equipment to ensure concrete placement with automated grade control to the correct vertically location and horizontal grade, but also to achieve the best possible ride measurement.  

GM required ride quality measurement of the new pavement surface. Based on the actual field MRI measurements and the “seat of your pants” ride measured by GM test drivers at speeds in excess of 150 mph, the newly placed pavement only required corrective action at one location in one lane of 18 lane miles of paving.   Reopening just short of the 53rd anniversary of the original opening date, the reconstructed track will continue to serve GM’s world-class automotive proving grounds. 

 

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* ACPA Member.

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