Traveling a New Road

After Peña Boulevard developed severe alkali silica reaction damage, the City and County of Denver began a $10 million repaving project. The new highway opened in late 2014 with a wider shoulder, cable rail for safety, and a new drainage system.

Castle Rock Construction Co. of Colorado won the bid to repave Peña Boulevard with portland-limestone cement concrete on a recycled stabilized road base. The contractor took extra measures to ensure pavement smoothness: feeding the paver with a concrete spreader, monitoring concrete placement with a real time profiler, and pulling a modified v-float behind the paver to reduce surface chatter.

Before: Over nearly 20 years, spalling on Peña Boulevard had developed to the point that repairs were virtually constant. DIA mitigated the problem by patching holes with a hot-applied polymer modified resin.

A look at the paving train: Castle Rock Construction’s paver with dowel bar inserter (dowel bars are shown, ready for insertion), is followed by a work bridge and a texture/curing machine that applies a curing compound to aid in concrete hydration.

The contractor runs a spreader in front of its slipform paver to evenly distribute piles of concrete from delivery vehicles and remove pressure from the paver.

Castle Rock Construction Co. rubblized the existing pavement in a three-step process, to be used as drainable road base. First a guillotine breaker broke the concrete into large pieces (shown in foreground), then a multi-head breaker crushed the pieces into 6-inch minus aggregate.

Finally, the contractor used a steel roller fitted with a Z-pattern grid on the drum face, operated in vibratory mode, to settle and seat the rubblized pavement. This also assists in crushing the top three inches of the pavement to a diameter of 2-inch minus.

Castle Rock Construction Co. installed a trench drain along the low side of the pavement, lined with geofabric, to relieve water from under the newly constructed portland-limestone cement concrete pavement.

Water runs from the road to drainage basins, keeping pavement dry and helping filter magnesium chloride deicers.

Denver International Airport invested in an MIT-2 scanner to test dowel bar placement in the new stretch of Peña Boulevard. The CDOT paving specification requires contractors to conduct tests with the scanner to show dowel bars inserter are placed according to specification tolerances.

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