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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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Presentation Transcript
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)