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7 March 20142014 Virginia Concrete Paving Conference,
Richmond, VA
DFW ConnectorPavement Design and Construction
Challenges and Solutions
By: Dan Dawood, P.E.
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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
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DFW Connector
Project Length: 8.4-mile initial phase of 14.4-mile project,
Existing 12 Lanes Expanding to 24 lanes
2-3 lanes 6-7 lanes 2 lanes
CL
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DFW Connector Design Tasks
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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
Pavement Design Tasks
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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)
CRCP Thickness Design
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Reinforcement Design
Adopted updated reinforcement standardCRCP (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
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#57 stone, pea gravel, and natural sand
Optimized PCCP Mix
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Toll Gantry Area Blockouts
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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
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Construction Schedule: 4 years (2010-2014)
Design-Build contracting process
Accelerated Construction Challenges and Solutions
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Keep all lanes open during peak travel times
Temporary pavement to shift traffic
Accelerated Construction Challenges and Solutions
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Keep all lanes open during peak travel times
Most lane closures scheduled to occur at night (off-peak)
Accelerated Construction Challenges and Solutions
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Varying paving widths:12’ lanes, 10’-12’ shoulders, 16’-24’ ramps10’, 12’, 16’, 22’ and 24’ paving widths
10”-13” paving thicknesses Short pours
due to MOT and bridge construction
Accelerated Construction Challenges and Solutions
EB & WB managed lanes – SH 114
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Four new Guntert & Zimmerman paversS600 – 10’-18’ paving widthsS850 – 18’-24’ paving widths
Accelerated Construction Challenges and Solutions
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Four new Guntert & Zimmerman paversStringless compatibleMobility – Tracks steer 90°Telescoping End Sections
Easy to change widths – 2 hrs
226 lane miles of CRCP (535,000 yd3)
Accelerated Construction Challenges and Solutions
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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
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Location of Batch Plant and Yards
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Completed Manage Lanes
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Leica Stringless System
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Leica Stringless System
North bound widening on SH121
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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)
www.thetranstecgroup.com