7 March 2014 2014 Virginia Concrete Paving Conference, Richmond, VA

1. DFW ConnectorPavement Design and ConstructionChallenges and Solutions 7 March 20142014 Virginia Concrete Paving Conference, Richmond, VA By: Dan Dawood, P.E.

2. 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

3. 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

4. DFW Connector Design Tasks

5. 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

6. 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)

7. 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

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

9. Toll Gantry Area Blockouts

10. 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

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

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

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

14. 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

15. Accelerated Construction Challenges and Solutions • Four new Guntert & Zimmerman pavers • S600 – 10’-18’ paving widths • S850 – 18’-24’ paving widths

16. 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)

17. 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

18. Location of Batch Plant and Yards

19. Completed Manage Lanes

20. Leica Stringless System

21. Leica Stringless System North bound widening on SH121

22. 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)

23. www.thetranstecgroup.com