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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