
Nominee
Iowa Highway 3 Accelerated Concrete Overlay
Category
Innovative Project
Description
The Iowa Hwy 3, Accelerated Work Concrete Overlay project aimed to demonstrate that a concrete overlay with an accelerated construction schedule could be completed in less time than a traditional schedule, while still maintaining the quality of the project and increasing safety.
Effective project management, scheduling, and communication were key to the success of the Iowa Hwy 3, Accelerated Concrete Overlay project. The project brought together multiple suppliers and subcontractors, each with their own specific responsibilities and timelines. The project schedule was tightly managed to ensure that all work was completed within the 25 calendar days. On average, 5,580 tons of material were used daily, which required close coordination between the suppliers, subcontractors, and Croell, Inc. leadership. Grading, paving, and final shouldering were all performed in a 2 to 3-mile stretch of the project, which required collaboration between the different teams to ensure that the work was completed on time. The project management team also had to be proactive in communicating with the community, local businesses and other stakeholders to inform them of the construction schedule and any disruptions to traffic flow. They also had to keep an open line of communication with the contractors and suppliers to ensure that the project was completed on time and within budget.
Overall, the Iowa Hwy 3, Accelerated Concrete Overlay project was a success, demonstrating that accelerated construction methods for concrete overlays can be completed quickly, efficiently and with minimal disruption to the community. This project serves as a model for other infrastructure upgrades that prioritize safety and community impact while delivering high quality results.
Evidence
The old philosophy for highway overlays was to close the road from end to end for months, to allow the contractor to work safely under a full closure. This caused significant disruptions to traffic flow, as through traffic was detoured for most of a summer and local traffic mixed with construction traffic.
The new test philosophy for the Iowa Hwy 3 project focused on reducing the impacts of the overlay on through traffic. By using lane closures and pilot vehicles as appropriate and detouring traffic for the shortest amount of time possible, through traffic was able to continue with minimal disruption.
The conventional method for a concrete overlay would take 60 working days to complete with traffic detoured for the whole project. A conventional asphalt overlay would take 60 working days using single lane closures. Both conventional methods would take 90 calendar days to complete. However, the Accelerated Concrete Overlay took just 25 calendar days with minimal closures to complete mainline paving.
The key features of this project were the use of accelerated construction and testing methods. These methods allowed for the concrete overlay to be placed and cured in a shorter amount of time than traditional methods, reducing the overall duration of the project and minimizing disruptions to traffic flow. The maturity method was used to test the opening strength of the concrete and allow traffic on the road as soon as possible. The concrete's maturity was based on 325 psi flexural strength, which allowed the road to be opened between 13 and 16 hours.
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