DFW Connector Pavement Design and Construction Challenges and

DFW Connector Pavement Design and Construction Challenges and Solutions 7 March 2014 Virginia Concrete Paving Conference, Richmond, VA By: Dan Dawood, P. E. 1

DFW Connector n Owner: Tx. DOT n D-B Firm: North. Gate Constructors n Lead Design: PB Americas n Pavement Design: Transtec n Cost: Over $1. 0 billion n Publicly funded CDA: ¨ $667 million from public gas taxes, www. dfwconnector. com ¨ $250 million from ARRA funds, and ¨ $107 million from bond proceeds for ROW acquisition. 2

DFW Connector n Project Length: 8. 4 -mile initial phase of 14. 4 -mile project, n Existing 12 Lanes Expanding to 24 lanes CL 2 -3 lanes 6 -7 lanes 2 lanes 3

DFW Connector Design Tasks 4

Pavement Design Tasks n n n n n 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 5

CRCP Thickness Design n 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) 6

Reinforcement Design n Adopted updated reinforcement standard ¨ CRCP (1) -03 n Longitudinal Steel 13” CRCP: #6 bar @ 5. 5” ¨ 10” CRCP: #6 bar @ 7” ¨ n 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 n Transverse steel: #5 @ 48” for PW up to 100 ft n 7

Optimized PCCP Mix n #57 stone, pea gravel, and natural sand 8

Toll Gantry Area Blockouts 9

Other Pavement Design Tasks n CRCP Transition Design ¨ CRCP to HMA ¨ CRCP to existing CRCP ¨ CRCP to new CRCP ¨ CRCP Thickness Transition n Design of Pavement Widenings ¨ Drainage Considerations ¨ Remaining Life of Existing CRCP ¨ Future Rehabilitation Needs n Pro. VAL Analysis - PI vs. IRI 10

Accelerated Construction Challenges and Solutions n Construction Schedule: 4 years (2010 -2014) n Design-Build contracting process 11

Accelerated Construction Challenges and Solutions n Keep all lanes open during peak travel times n Temporary pavement to shift traffic 12

Accelerated Construction Challenges and Solutions n Keep all lanes open during peak travel times n Most lane closures scheduled to occur at night (off-peak) 13

Accelerated Construction Challenges and Solutions n Varying paving widths: ¨ 12’ lanes, 10’-12’ shoulders, 16’-24’ ramps ¨ 10’, 12’, 16’, 22’ and 24’ paving widths 10”-13” paving thicknesses n Short pours due to MOT and bridge construction n 14 EB & WB managed lanes – SH 114

Accelerated Construction Challenges and Solutions n Four new Guntert & Zimmerman pavers ¨ S 600 – 10’-18’ paving widths ¨ S 850 – 18’-24’ paving widths 15

Accelerated Construction Challenges and Solutions n Four new Guntert & Zimmerman pavers ¨ Stringless compatible ¨ Mobility – Tracks steer 90° ¨ Telescoping End Sections n Easy to change widths – 2 hrs ¨ 226 lane miles of CRCP (535, 000 yd 3) 16

Terex Batch Plant Model S Rex. Con Dual Drum 12 yd 3 plant n Capacity 600 yph. n Typical batch size is n ¨ 11 yd 3 on flowboy rear discharge trailers ¨ 7 yd 3 on tandem dump trucks 17

Location of Batch Plant and Yards 18

Completed Manage Lanes 19

Leica Stringless System 20

Leica Stringless System North bound widening on SH 121 21

Leica Stringless System Advantages: n Smoother ride n Eliminates man-hours in the field (production and safety). n Eliminates schedule impacts/coordination (stringline setup/removal). n Flexibility ¨ Haul route ¨ Trucks entrances and exits ¨ jump around from area to area (easier set-up) 22

www. thetranstecgroup. com 23