...December 21, 2007
Volume 43, Number 12...

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Exceeding Expectations
High-Performance Highways
State-of-the-Art Runways
Beautiful Streets

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Special Edition:
Setting the Standard in Excellence
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Exceeding Expectations
 
     
  (Editor's Note: This is the second in a two-part series highlighting projects recognized as part of the 18th Annual Excellence in Concrete Pavements Awards.)

 
 

This issue of CONCRETE PAVEMENT PROGRESS showcases the winners of the silver-level "Excellence in Concrete Pavement Awards" presented by the American Concrete Pavement Association.

The project descriptions below highlight some of the outstanding workmanship and other fine points associated with placing and rehabilitating concrete pavements throughout the nation.

 

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High-Performance Highways
 
     
  Safe, durable, and cost-effective are just a few words that describe the inherent benefits of concrete pavements. Now, when all of those features are combined with exceptional quality, superb workmanship, and skilled craftwork, the end result is an award-winning pavement! Here are some of the highlights of the silver-class winners of the ACPA Excellence in Concrete Pavement Awards for highways.  
     
 

Concrete Keeps Traffic Moving … This project required multiple phases to complete reconstruction while accommodating heavy traffic flow. By using effective planning, however, the project team was able to incorporate concrete pavement construction while meeting the needs of motorists.

This 9.81-mile project involved removing concrete pavement built in 1967, recycling it for base course, and reconstructing four lanes of interstate pavement. The project also involved

 
  widening three out of four bridges on the project and placing a 3-in. bonded concrete overlay on all four bridges.

A five-phase traffic and construction plan was necessary to allow two lanes of traffic open in each direction at all times to accommodate 60,000 vehicles per day.


ACPA recognized this project as its Silver Co-winner: Divided Highways-Rural, presented to (contractor) Duininck Bros, Inc. and (owner/engineer) Texas Department of Transportation, Paris District. 
   
... ... Flexibility and wise planning produced a beautiful, smooth ribbon of concrete pavement in Texas. ...
     
... Team Achieves Quality Goals on Highway Project ... The project team for the Route 367 freeway conversion set three goals: create a quality product, deliver it on time, and do it all in a cost effective manner.

The project converted Route 367 into an elevated, uninterrupted freeway.

The contractor incorporated several improvements, including the use of concrete base instead of asphalt, which saved the owner time at no additional
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  cost. Seven value engineering proposals, including one that changed the mainline pavement from 12 in. to 10   Value engineering proposals to the construction plan saved the DOT money on this conversion project.  
  in. of concrete pavement, saved the DOT more than $780,000.

ACPA recognized this as the Silver Winner: Divided Highways-Urban project, presented to (contractor) Fred Weber, Inc.; (owner) Missouri Department of Transportation; and (engineer) HDR Engineering, Inc.
 
     
  Crews Conquer Hidden Surprises ... Contracting crews weren't deterred when they uncovered a number of surprises when replacing the existing Highway 18 to build an interchange for the long-anticipated Highway 60 "Sheldon Bypass" in Iowa.

 
   

Originally built in the 1930's, the highway required the removal of 18 inches of asphalt overlay.

Additional challenges, such as an unplanned detour route, did not phase the project team—the contractor used a value engineering proposal with an on-site detour to save taxpayers six weeks of inconvenience and thousands of dollars.

The end product is a beautiful ribbon of smooth, concrete pavement to serve north-south travelers in western Iowa.

 
... Building an interchange for the Highway 60 "Sheldon Bypass" included a number of unforeseen challenges. ... ...
 
ACPA awarded this as Silver Co-winner: Divided Highways-Rural, presented to (contractor) Cedar Valley Corp. and (owner/engineer) Iowa Department of Transportation.
 
     
  Coordinating Smoothness ... Coordination and innovation were the keys to success in creating a smooth ride in St. Louis.

The project team fought freezing temperatures while performing all major work at night, coordinating simultaneous lane drops within a tight schedule and managed heavy truck traffic at all times.

State-of-the-art technology in diamond grinding also aided the team in creating excellent smoothness on this 12.5-mile stretch of Route 370 in the greater St. Louis metropolitan area.

Project work over the 39 lane miles included full and partial depth repairs; dowel bar retrofitting; lifting approaches and slabs; and shoulder milling and repairs.
   
  ACPA recognized this as the Silver Co-winner: Concrete Pavement Restoration, presented to (contractor) Penhall Company and (owner/engineer) Missouri Department of Transportation.   Coordination and innovation provided a smooth ride in the St. Louis, Mo., area.  
     
    Night Construction Results in Savings ... Repair and scheduling strategies helped the project team overcome a number of significant hurdles presented by the high-profile, Interstate 25 slab replacement in Ft. Collins and Loveland, Colo.

Conducted on a busy stretch of Interstate 25 at multiple locations, the project required contractor Concrete Works of Colorado to perform all work between 9 p.m. and 5 a.m. and then re-open the lanes to traffic each day.
 
  Night paving for this busy stretch of highway provided a solid traffic management plan and resulted in cost savings for the agency.  
The end product provided owner CDOT with a cost-effective, restored roadway to hold up to heavy traffic.
 
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ACPA recognized this as the Silver Co-winner: Concrete Pavement Restoration, presented to (contractor) Concrete Works of Colorado; (owner) Colorado Department of Transportation (CDOT); and (engineer) CDOT-Region 4 Materials.
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Engineering Judgment Calls for Concrete ... The existing pavement on the Muskogee Turnpike in Wagoner County, Okla., included a faulting asphalt overlay that wasn't holding up to traffic. The project team used solid engineering judgment and leadership to make this project easier, cheaper, and faster than the original project plan to fix the ailing asphalt overlay. Originally, the project was to include more than $650,000 worth of barrier wall movements for paving 24' wide with no traffic. However, the contractor proposed paving 12' lanes directly next to traffic for maximum paving and driving efficiency.

The project included 48 lane miles of 3 in.-thin bonded concrete overlay, providing the Oklahoma Turnpike Authority with a longer-lasting solution and an improved ride.

 
  The contractor achieved a smoothness of 1.5" per mile using a .20 blanking band and earned 62% of the available bonus, surpassing the turnpike authority’s expectations.

The end product is a better road built with concrete, placed under traffic like asphalt.

ACPA recognized this as the Silver Winner: Overlays–presented to (contractor) Duit Construction Company, Inc.; (owner) Oklahoma Turnpike Authority; and (engineer) Tetra Tech, Inc.
   
... ... The project team used concrete pavement and solid engineering judgment to make this project easier, cheaper, and faster. ...

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State-of-the-Art Runways
 
     
... Sustainability Meets Function on Runway De-Ice Pad ... The contractor incorporated environmentally friendly processes into a state-of-the-art de-icing pad at Denver International Airport. The new facility not only performs the intended function of de-icing of aircraft, but also monitors and collects water to send to the wastewater treatment facility or store for recycling. This also results in significant labor and cost savings.
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  The project involved working on a site located between two active taxiways, removal and replacement of concrete panels at a busy intersection, and placing and finishing as many as 12 headers while completing two paving lanes in a day.

Despite difficult site conditions, the team worked with airport operations to complete the project ahead of time and delivering a quality product to the owner.
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ACPA named this project the Silver Co-winner: Commercial Service & Military Airports, presented to (contractor) Interstate Highway Construction, Inc.; (owner) City and County of Denver’s Department of Aviation; and (engineer) Carter & Burgess, Inc.
 
  The contractor incorporated wastewater management into the state-of-the-art concrete pavement de-icing pad at Denver International Airport.  
     
  Innovative Construction Trims Schedule ... Innovative construction methods cut nearly three months off the allotted time schedule for the reconstruction of Taxiway K at Dallas/Ft. Worth International Airport. This achievement is especially noteworthy since, due to the high air traffic at DFW, the airport required the contractor to complete concrete paving operations at night.
 
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In addition to the safety hazards of night paving, the site also included impalement hazards on sleeper slabs, limited access, and confined work areas for equipment.

Yet the contractor rose to the challenge by partnering with all stakeholders, rephrasing the original plan and saving time without sacrificing safety or quality.

ACPA recognized this project as the Silver Co-winner: Commercial Service & Military Airports, presented to (contractor) Granite Construction Company; (owner) Dallas/Ft. Worth International Airport (DFW); and (engineer) DMJM Aviation.

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Night paving with concrete pavement allowed flights to continue while construction occurred.

   
     
... Runway's Concrete Facelift to Support Growing Traffic ... This project gave the Charles B. Wheeler Downtown Airport the facelift it needed to continue serving a large number of local companies in the Kansas City, Mo. area.

Improvements included the removal and replacement of Runway 1-19, as well as transverse joints, piping, and extensive utility work.

The contractor conducted work in three phases so that small planes could still use part of the runway while construction took place.

A solid communication plan and coordination on these improvements among all stakeholders also ensured that the end product satisfied the owner, provided a quality runway for local businesses, and maintained the safety of all involved.
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ACPA recognized this project as the Silver Winner: Reliever & General Aviation Airports, presented to (contractor) Loch Sand & Construction Company; (owner) City of Kansas City Aviation Department; and (engineer) TranSystems.
  Concrete pavement improvements made this runway ready to support growing local businesses.  

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Beautiful Streets
 
     
  When it comes to local roads, taxpayer demands rule supreme. Concrete pavement not only provides a solid option as many of these projects demonstrate, but also fills the need for beautiful roads that instill pride in residents.


 
 

City Chooses Concrete Aesthetics ... Concrete pavement's aesthetics, as well as many safety, cost, and congestion mitigation benefits, led the City of Springfield, Ore., to choose it over asphalt for the four-lane arterial connection between two busy parts of town.

The City conducted a 40-year life cycle cost analysis and chose concrete pavement for the Martin Luther King, Jr. Parkway and Roundabout construction based on its projected low maintenance costs, as well as the additional potential to save on lighting and energy.

This project included the first complete multi-lane roundabout in the state, chosen for its aesthetics, vehicle capacity, and ability to improve the intersection's safety. This project is part of a ten-year program in commuting and transportation improvements.

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  Overall, the project included the construction of more than 69,000 square yards of concrete pavement for surfaces and driveways; more than 3,500 cubic yards of concrete curbs and gutters; and red colored and stamped concrete and attractive concrete block walls.   The project included a concrete pavement roundabout for intersection safety, vehicle capacity, and enhanced aesthetics.  
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ACPA awarded this project the Silver Co-winner: Municipal Streets & Intersections (>30,000 SY), presented to (contractor) Delta Construction Company; (owner) City of Springfield; and (engineer) Lane County Public Works—Engineering Division.
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Avenue Overhaul Completed in Time for Golf Tournament ... This project upgraded Kelly Avenue from an existing four-lane undivided asphalt arterial roadway into a divided four-lane route with center medians, major landscaping, and decorative sidewalks—all delivered on time to facilitate traffic generated by a major golf tournament.

Project work included removing 6 to 8 inches of asphalt surface, excavate to new grades, installing all new storm drainage structures, install 8 inches of fly ash modified subgrade, place a 3-in. asphalt base course, and then placing a surface course of 9-in. jointed plain doweled concrete pavement. Challenges included accommodating traffic, side streets, and businesses and commercial driveways along the way.
Yet the project team worked closely to complete all activities 59 days early.

   
 
Additionally, the City was so pleased with the quality of materials and workmanship that they anticipate using more concrete for future pavement projects.
 
... This project upgraded Kelly Avenue into a four-lane route with center medians, landscaping, and decorative sidewalks. ...
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ACPA awarded this project the
Silver Co-winner: Municipal Streets & Intersections (>30,000 SY)–presented to (contractor) TTK Construction Company, Inc.; (owner) Oklahoma Department of Transportation; and (engineers) City of Edmond and Clowers Engineering Co.
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Concrete Pavement Replaces Asphalt for Corridor Improvement ... Concrete pavement was chosen for its versatility for the Reconstruction of Routes 36 and 408 in the village of Mt. Morris and towns of Mt. Morris and Leicester in Livingston County, N.Y.

The scope included replacing the existing asphalt with new concrete pavement on several routes critical for local tourism, businesses, and commuters.

 
  Concrete pavement's flexibility for varied work zone length and size made it the best choice for this reconstruction project.
 ...

The project team used high early-strength concrete for early reopening of all pavements.

 
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The project team's ability to vary the length and size of work zones during the project’s eight-phase-long plan, as well as paving methods, played a big part in the project's success. The end product provides enduring strength and attractive roadways, with reduced long-term maintenance costs.

ACPA recognized this as the Silver Winner: Municipal Streets & Intersections (<30,000 SY)–presented to (contractor) Surianello General Concrete Contractor, Inc.; (owner) New York State Department of Transportation; and (engineer) URS Corporation.
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Persistence, Consistency Pay Off ... Constant communication among stakeholders and with the City of St. Charles Public Works Department ensured this project was a smooth one, both in end-product and in minimizing impact on the traveling public.

This project extended North Fifth Street in St. Charles, Mo., a total of 4,892 linear feet to the north, including the construction of a 530-ft.-long bridge and a number of aesthetic improvements for a long-lasting, eye-pleasing product.

The contractor consistently worked with stakeholders to ensure quality. Concrete slump and air content were continually monitored at the batch plant; fine and coarse aggregate gradation was constantly checked for standards; and cement, fine, and coarse aggregate proportions also were monitored.

 
    The team also conducted regular weekly and bi-weekly meetings with the city, as well as used a number of resources to communicate project progress to the traveling public. The end product is a smooth pavement that earned the contractor 100% of available incentives for smoothness, completed seven months ahead of schedule.  
... Constant communication ensured the proper measures were taken to produce a quality concrete pavement. ... This project is the Silver Co-winner: Urban Arterials & Collectors–presented to (contractor) Millstone-Bangert, Inc.; (owner) City of St. Charles – Public Works Department; and (engineer) Kuhlmann Design Group. ...
     
  Rapid Reconstruction Improves Industrial Route ... Accelerated concrete pavement reconstruction, as well as new construction, improved S.R. 711 in Youngstown, Ohio, for area motorists and provided better access to industrial sites.

 
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The construction team implemented a number of quality measures at all stages of construction to ensure quality. Among these efforts were a central mix plant next to the project site and close attention to trackline placement.

Despite hold-ups from a separate contract to fill existing coal mines, as well as the challenge of varied lane width at ramps and side roads, the project team opened the route six weeks early.

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  Accelerated construction improved this critical route for access to local industrial sites.  
ACPA recognized this as the Silver Co-winner: Urban Arterials & Collectors, presented to (contractor) The Great Lakes Construction Co.; (owner) Ohio Department of Transportation (ODOT); and (engineer) GPD Group.
 
     
  Innovative Mixture Design, Staging Support Rodeo Fans ... Uncooperative weather conditions and a rapidly approaching rodeo event posed challenges from the beginning of this project, but a close partnering effort ensured that the construction of Highway 2 - Sidney Bypass in Fremont County, Iowa, was a success.

The project team ran a series of trial mixture designs to overcome challenges from local coarse aggregate. The new mixture increased the coarse aggregate from 40% to 45%, had superior gradation, and resulted in the contractor earning the maximum incentive for designing a concrete mixture with an optimum, combined aggregate gradation.

 
  The contractor also improved the original staging plan to reduce inconvenience to motorists, while optimizing the pavement's constructability and assuring smoothness.

Because of extraordinary rainfall, the project experienced some delays. With more than 10,000 fans heading to town for a rodeo, the construction team needed to do something to meet the deadline. Through a close partnership effort, the team overcame setbacks from wet weather, poor soil conditions, and aggregate mix to complete the project under a tight 75-day schedule.
   
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ACPA recognized this as the Silver Winner: State Roads, presented to (contractor) Cedar Valley Corp.; (owner) Iowa Department of Transportation; and (engineer) HGM Associates, Inc.
 
... Innovative mixture design was the solution for aggregate challenges on this project. ...

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ACPA Concrete Pavement Progress is published 12 times per year and covers current practices and case histories in the concrete pavement industry. ACPA Concrete Pavement Progress is distributed free of charge to public officials, ACPA members, executive committee, board of directors, and affiliated chapter/state paving associations.

All rights reserved. Copyright 2007 by the American Concrete Pavement Association. No portion of this publication may be reproduced mechanically or electronically without the expressed written permission of the American Concrete Pavement Association.


American Concrete Pavement Association
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Phone: 480-775-0908


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2007 Chairman, ACPA Board of Directors
Pat Nolan, Interstate Highway Const., Inc. (IHC)

2007 Vice-Chairman, ACPA Board of Directors
Kari Saragusa, Lehigh Cement Co.

ACPA President/CEO - Gerald F. Voigt, P.E.
Editor - Bill Davenport
Managing Editor - Erin McKnight


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