I-75, Birch Run Creek to Bridgeport Interchange at Saginaw Co, MI
Project Focus
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Project Details
Construction & Complexity
This project consisted of 4 - 12' lanes, a 12' outside shoulder and a 5.6' inside shoulder. It was essential to coordinate the paving sequence so that the project could proceed with minimum interruptions while waiting on cure time. The Contractor paved the median lane first in most areas in order to allow completion of the valley gutter and restore project drainage. Recycling of the old pavement to re-use for open-graded base provided both time and resource savings. Several storm water pipes, up to 25' deep, that crossed the road added to the complexity of the project as each required substantial deep sheeting and dewatering to accommodate the traffic while the storm sewer was placed in phases.
Concrete was mixed at the project site with a Rex Model-S central mix plant and delivered to the grade with a steady supply of trucks to maintain a continuous flow to the concrete paver. Aggregate gradation was optimized using a "Shilstone" type process to provide a mix with excellent workability as well as meeting the performance criteria. This was important in achieving the smoothness with cost-effective mix. A tube machine was also used to help improve smoothness and seal the surface of the pavement. Directly behind the paver were two straight edge finishers to help take care of any irregularities before the tube machine.
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Innovation
A moveable barrier wall concept was used to provide 3 lanes of traffic in the high flow direction. This innovation was cost effective since it reduced the temporary widening to accommodate the traffic during construction.
A new Barrier Gate System, the first of its kind in Michigan, was installed in the median barrier wall, allowing authorized vehicles key code entry. Providing critical access to the opposite roadway without going to the nearest interchange greatly improves the facility for fast action in emergency situations.
Recycling of the entire old concrete pavement for use as an aggregate for open graded base under the new concrete shoulders and median paving was a major contribution to a sustainable solution, improving safety, congestion and economy by reducing the number of construction trucks that would have been required using traditional construction methods.
Quality
Our process controls resulted in a 4400 psi average compressive strength of the concrete for pavement reliability exceeding the contract requirement. Pavement smoothness requirements were met with a minimum of bump grinding. We were required to provide a 5-year material and workmanship warranty on the concrete pavement. Our quality control program requires the development of a project-specific Quality Control Plan (QCP) to ensure all contract requirements for quality are met and to provide the necessary documentation. A full-time project Quality Control Manager reporting directly to the corporate Quality Control manager is responsible for the execution of the QCP. Dowel bar placement by the automatic DBI was assured with wet checks during PCCP placement and with non-destructive methods
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Public Relations
Weekly progress meetings were held and the public was kept informed of any upcoming closures or openings. These announcements were made on the radio, TV and in local newspapers. MDOT also used their website as a way to keep the media and public informed.