I-76 Design-Build Near Hudson, CO

Project Focus
This $32.6 million project reconstructed 9.4 miles of I-76 from Hudson to Keenesburg, an important link in fast-growing northeast suburban metro Denver. This is the fifth, and most complicated, in a line of limited scope Design-Build projects that CDOT has used since 1997 to accelerate the delivery of critical projects. In this process, CDOT directs the pavement options that are available to the contractor, permitting unbonded overlay or complete removal and replacement. The Contractor teamed with a highly qualified, local civil consulting engineer to ensure that all design requirements complied with sight distance, vertical and horizontal alignment, and to ensure that all options optimized the cost and schedule of the project. The lump sum bid for the project, a unique contracting method used by CDOT only for Design-Build to encourage the innovation of the DB team, provided the additional challenge of developing sufficient quantity and other pertinent information to control the bid risk.

One of the main benefits of this Design-Build method is that it enables the projects to start sooner as plans and specification development need not be 100% complete before the construction is started. This saved up to six months on project development prior to the start of construction. The partnering process required the formation of a "Design Leadership Team" (DLT) to facilitate the rapid development of final design and ensure that the design schedule of work, review, dispute resolution and approval did not delay construction of the project.

Project Details
Schedule & Complexity
The project was originally scheduled for completion on November 1, 2001, but was completed by October 23, 2000, more that a year ahead of schedule. Tom Norton, the CDOT Executive Director said, “success was due to implementation of the design-build process by the prime contractor and their subcontractors. The way they managed their work allowed us all to set and meet a pretty aggressive schedule.” The contracting team appreciates these accolades from a satisfied customer as a job well done; however, we recognize the full cooperation and partnership developed with CDOT and other stakeholders was integral to our success.

Construction & Innovation
Formal partnering resulted in excellent communication throughout with problems solved at the core level providing a good working environment for all.

The Contractor worked with CDOT and the local community of Hudson during the design phase, and during construction, to leave something better, beyond the original scope of the project. Under a new traffic management plan, the team was able to delete a temporary crossover access ramp by improving a local road that provided the necessary access. At the end of the project, the improved road remained for the community. Hudson requested, and received, placement of new utility sleeves.

The Contractor also proposed significantly raising the grade at the reconstructed SH-52 overpass during the design phase. This innovative change resulted in overlaying mainline I-76 rather than removing and replacing. It also solved state environmental department concerns regarding exposing a wet and potentially hazardous subgrade. As part of this innovative solution, the Contractor successfully corrected the cross-slope in a major super-elevated curve by slipforming a full-width 38’ tapered section varying up to 37” on the high edge.

Quality
CDOT required that the contractor be responsible for quality control on all processes with full documentation of tests and inspection. CDOT maintained QA functions utilizing an efficient statistical verification of the contractor’s tests. The built in quality received incentive rewards for excellent processes to control strength, thickness and smoothness.