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DFW Connector Pavement Design and Construction Challenges and Solutions. 7 March 2014 2014 Virginia Concrete Paving Conference, Richmond, VA. By: Dan Dawood, P.E. DFW Connector. Owner: TxDOT D-B Firm: NorthGate Constructors Lead Design: PB Americas Pavement Design: Transtec

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7 march 2014 2014 virginia concrete paving conference richmond va

DFW ConnectorPavement Design and ConstructionChallenges and Solutions

7 March 20142014 Virginia Concrete Paving Conference, Richmond, VA

By: Dan Dawood, P.E.


Dfw connector
DFW Connector

  • Owner: TxDOT

  • D-B Firm: NorthGate Constructors

  • Lead Design: PB Americas

  • Pavement Design: Transtec

  • Cost: Over $1.0 billion

  • Publicly funded CDA:

    • $667 million from public gas taxes,

    • $250 million from ARRA funds, and

    • $107 million from bond proceeds for ROW acquisition.

www.dfwconnector.com


Dfw connector1
DFW Connector

  • Project Length: 8.4-mile initial phase of 14.4-mile project,

  • Existing 12 Lanes Expanding to 24 lanes

CL

2-3 lanes

6-7 lanes

2 lanes



Pavement design tasks
Pavement Design Tasks

  • Thickness design

  • Reinforcement design

  • Temporary pavement design

  • Block-out solutions

  • Terminal joint design

  • Pavement transitions

  • Pavement widenings

  • Gore area design

  • Mix and materials

  • Resilient modulus verification


Crcp thickness design
CRCP Thickness Design

  • PCC Thickness Design

    • 10” CRCP for Frontage Roads

    • 13” CRCP for Main lanes, Ramps, and Managed lanes

    • 2.5” HMA Base Layer

    • 12-36” Lime Stabilized Subgrade/Crushed Concrete Base (Effective Plasticity Index Requirements)


Reinforcement design
Reinforcement Design

  • Adopted updated reinforcement standard

    • CRCP (1) -03

      • Longitudinal Steel

        • 13” CRCP: #6 bar @ 5.5”

        • 10” CRCP: #6 bar @ 7”

      • Transverse steel

        • Varies as a function of pavement width (PW)

        • For 13”: #6 @ 2.5’ for PW < 60 ft up to @1.0’ for PW < 120 ft,

          CRCP (1) -09

      • Same Longitudinal Steel as CRCP (1) -03

      • Transverse steel: #5 @ 48” for PW up to 100 ft


Optimized pccp mix
Optimized PCCP Mix

  • #57 stone, pea gravel, and natural sand



Other pavement design tasks
Other Pavement Design Tasks

  • CRCP Transition Design

    • CRCP to HMA

    • CRCP to existing CRCP

    • CRCP to new CRCP

    • CRCP Thickness Transition

  • Design of Pavement Widenings

    • Drainage Considerations

    • Remaining Life of Existing CRCP

    • Future Rehabilitation Needs

  • ProVAL Analysis - PI vs. IRI


Accelerated construction challenges and solutions
Accelerated Construction Challenges and Solutions

  • Construction Schedule: 4 years (2010-2014)

  • Design-Build contracting process


Accelerated construction challenges and solutions1
Accelerated Construction Challenges and Solutions

  • Keep all lanes open during peak travel times

  • Temporary pavement to shift traffic


Accelerated construction challenges and solutions2
Accelerated Construction Challenges and Solutions

  • Keep all lanes open during peak travel times

  • Most lane closures scheduled to occur at night (off-peak)


Accelerated construction challenges and solutions3
Accelerated Construction Challenges and Solutions

  • Varying paving widths:

    • 12’ lanes, 10’-12’ shoulders, 16’-24’ ramps

    • 10’, 12’, 16’, 22’ and 24’ paving widths

  • 10”-13” paving thicknesses

  • Short poursdue to MOT and bridge construction

EB & WB managed lanes – SH 114


Accelerated construction challenges and solutions4
Accelerated Construction Challenges and Solutions

  • Four new Guntert & Zimmerman pavers

    • S600 – 10’-18’ paving widths

    • S850 – 18’-24’ paving widths


Accelerated construction challenges and solutions5
Accelerated Construction Challenges and Solutions

  • Four new Guntert & Zimmerman pavers

    • Stringless compatible

    • Mobility – Tracks steer 90°

    • Telescoping End Sections

      • Easy to change widths – 2 hrs

    • 226 lane miles of CRCP (535,000 yd3)


Terex batch plant model s
Terex Batch Plant Model S

  • RexCon Dual Drum 12 yd3 plant

  • Capacity 600 yph.

  • Typical batch size is

    • 11 yd3 on flowboy rear discharge trailers

    • 7 yd3 on tandem dump trucks





Leica stringless system1
Leica Stringless System

North bound widening on SH121


Leica stringless system2
Leica Stringless System

Advantages:

  • Smoother ride

  • Eliminates man-hours in the field  (production and safety).

  • Eliminates schedule impacts/coordination (stringline setup/removal). 

  • Flexibility

    • Haul route

    • Trucks entrances and exits

    • jump around from area to area (easier set-up)



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