I-66 Pavement Rehabilitation

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1 I-66 Pavement Rehabilitation Fall Asphalt Conference Richmond, VA David Shiells, P.E. Virginia Department of Transportation David White Superior Paving Corporation October 2, 2012

2 Project Location 2

3 Goal Provide a cost effective pavement rehabilitation that will last for 20 years with minimum disruption to the traveling public Challenges for Pavement Rehabilitation Limited space for Maintenance of Traffic (MOT) Limited times for dual lane closures Limited overhead clearance for existing bridges Drainage Concrete barriers Lane shifts across longitudinal joints in concrete Coordination with adjacent Mega Projects 3

4 Pavement Structure Original Construction, 1960 to concrete pavement, wire mesh reinforcement, 61.5 transverse joint spacing 6 plain aggregate 6 soil cement 20-year design life; design ADT was 22,350 vpd Widening, 1990 to 1993 Original 2 lanes widened to 4 lanes (Route 50 to east of Route 123) 3 lanes widened to 4 lanes (east of Route 123 to I-495) Outside shoulder used as fourth lane during peak demand periods 11 concrete pavement, 15 transverse joint spacing 4 Stabilized open graded drainage layer 6 Cement treated aggregate (CTA) 4

5 Pavement Condition Summary of Condition Data Average CCI of 58 in 2007; range from 13 to 86 36,500 sy of patching mainline; 9,850 sy of patching on ramps/loops/cd roads Distresses concentrated in distinct areas 15% of transverse joints failing in load transfer based on 1995 FWD testing Courtesy: American Concrete Pavement Association Concrete Paving: Pavement Rehabilitation Strategy Selection 5

6 Pavement Condition Old Pavement in Poor Condition Approximately 20% of total pavement area in poor condition Distresses generally at transverse joints Isolated slabs have distress (spalling) throughout 6

7 Pavement Condition Significant Amount of Good Pavement Some pavement is in good condition Some patches in good condition Pavement in good condition between transverse joints 7

8 Challenges for Pavement Rehabilitation Limited Space for Maintenance of Traffic Outside shoulder is currently used as travel lane in peak hours (5:30 am to 11:00 am EB and 2:00 pm to 8:00 pm WB) Inside shoulder is only 2-8 wide No shoulders at some bridge locations; no shoulders on CD road at Nutley Street (retaining walls) Shoulder Lane Minimal Shoulder Shoulder Lane 8

9 Challenges for Pavement Rehabilitation Limited Times for Dual Lane Closures Weekdays 10:00 pm to 5:00 am (EB)/6:00 am (WB) Saturday and Sunday 7:00 pm to 9:00 am HOV Lane 9

10 Vehicles in 15 min Vehicles in 15 min Vehicles in 15 min Vehicles in 15 min Challenges for Pavement Hourly Traffic Volumes Average Volume in 15 minutes at Det 392 Group at MP (EB Friday) Rehabilitation Average Volume in 15 minutes at Det 411 Group at MP (WB Friday) 2,500 6:00 am 7:00 pm 6:00 am 8:00 pm 2,500 2,000 2,000 1,500 1, :00:00 1:00:00 2:00:00 3:00:00 4:00:00 5:00:00 6:00:00 7:00:00 8:00:00 9:00:00 10:00:00 11:00:00 12:00:00 Time 13:00:00 14:00:00 15:00:00 16:00:00 17:00:00 18:00:00 19:00:00 20:00:00 21:00:00 22:00:00 23:00:00 Average Volume in 15 minutes at Det 392 Group at MP (EB Saturday) MEAN_VOL +20% -20% 1,500 1, :00:00 1:00:00 2:00:00 3:00:00 4:00:00 5:00:00 6:00:00 7:00:00 8:00:00 9:00:00 10:00:00 11:00:00 12:00:00 Time 13:00:00 14:00:00 15:00:00 16:00:00 17:00:00 18:00:00 19:00:00 20:00:00 21:00:00 22:00:00 23:00:00 Average Volume in 15 minutes at Det 405 Group at MP (WB Saturday) MEAN_VOL +20% -20% 1,800 1,600 1,400 9:00 am 7:00 pm 10:00 am 7:00 pm 1,800 1,600 1,400 1,200 1,200 1, :00:00 1:00:00 2:00:00 3:00:00 4:00:00 5:00:00 6:00:00 7:00:00 8:00:00 9:00:00 10:00:00 11:00:00 12:00:00 Time 13:00:00 14:00:00 15:00:00 16:00:00 17:00:00 18:00:00 19:00:00 20:00:00 21:00:00 22:00:00 23:00:00 MEAN_VOL +20% -20% 1, :00:00 1:00:00 2:00:00 3:00:00 4:00:00 5:00:00 6:00:00 7:00:00 8:00:00 9:00:00 10:00:00 11:00:00 12:00:00 Time 13:00:00 14:00:00 15:00:00 16:00:00 17:00:00 18:00:00 19:00:00 20:00:00 21:00:00 22:00:00 23:00:00 MEAN_VOL +20% -20% 10

11 Challenges for Pavement Rehabilitation Limited Overhead Clearance for Existing Bridges 13 bridge structures; 7 Less than (2 less than 16-6 ) 16-1 Cedar Lane, WB 11

12 Challenges for Pavement Rehabilitation Drainage Inlets extend into shoulder travel lane Inlet extending into travel lane Shoulder Lane 12

13 Challenges for Pavement Rehabilitation Concrete Barriers Median and WMATA (5 miles locked in ) WMATA Barrier Retaining wall Median Barrier Shoulder Lane 13

14 Challenges for Pavement Rehabilitation Lane shifts across Longitudinal Joints in Concrete Longitudinal joint crossing wheel paths 14

15 Challenges for Pavement Rehabilitation Co-ordination with adjacent Mega Projects I-495 HOT Lanes Dulles Rail 15

16 Project Approach Development Met with industry associations (concrete and asphalt) on May 20, 2008 Received industry suggestions/proposals on June 18, 2008 Provided follow-up comments to industry Follow-up details received from industry on June 23 and June 24, 2008 Performed comparison of alternatives Project was funded and advertised in September, 2010 Delivery mechanism was design-build (pavement repairs specifically identified on RFP plans) Awarded to Fort Myer Construction Company on December 20, 2010 Total Contract Amount - $37.9 million 16

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22 Scope of Work Existing Median or Metro Barrier, depending on location v y z w x { Travel Lane 1 (HOV) u Travel Lane 2 Travel Lane 3 Aux. Travel Lane 6 ± u Patch badly deteriorated concrete pavement with full-depth concrete patches and seal joints v Patch minor spalling with asphalt w Seal joints, eradicate pavement markings, remove snow plowable raised pavement markers x Place 5/8 Thin Hot Mix Asphalt Concrete Overlay stress absorbing membrane interface layer y 2 SMA-12.5 (PG 76-22, polymer modified) z 1-1/2 SMA-9.5 (PG 76-22, polymer modified) { 3/8 High Friction Surface Course to delineate auxiliary travel lane 22

23 Scope of Work Issues: All existing barriers (both WMATA and median) have 2 reveal; reconstruct/re-face existing barriers but not WMATA barrier due to modifications required for existing drainage inlet throats Existing cross slope on auxiliary travel lane varied up to 8.3%; bring this up to standard (except at tapers beneath existing bridges) Design exception for cross slope up to 12.6% on inside shoulder Taper build-up to zero beneath low clearance bridges; survey and drainage analysis needed Adjust drainage inlets and grates in auxiliary shoulder lane 23

24 Concrete Patching Extremely rough pavement with failed patches and joints Full depth concrete patches 24

25 Concrete Patching Patch minor spalls with asphalt or partial depth patches 25

26 Concrete Patching Total 55,572 sy full-depth (12,004 EB; 36,214 WB; 7,355 on Ramps) 4,697 sy partial depth 26

27 THMACO Pavement surface very rough after concrete patches Spray bar paver Heavy tack 27

28 SMA Overlay 2 SMA-12.5 (76-22) Scratch course for leveling 1.5 SMA-9.5 (76-22) 28

29 Transitions Begin/end of overlay Beneath low clearance bridges Highways for Life section of post-tensioned pavement 29

30 Concrete Jersey Barrier Retrofit 23,600 lf with constant slope barrier Slip-form over existing barrier Drainage inlets required special formwork 30

31 Final Rideability Average IRI (ins/mi.) Lane EB WB Note: project design-build specification required average IRI < 70 ins./mi. with no individual 0.01 mile section >80 ins./mi. 31

32 High Friction Surface Course Delineate part-time shoulder pavement with a different color as a safety improvement 32

33 Delivered Fall 2012 a safer, and smoother, I-66! 33

34 Questions?

SECTION III-06 Surfacing Page 1 Revised 3/2/10. See the DESIGN GUIDELINES in Section I-06 for requirements for cross slope of the roadway.

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